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Document No.

GP 30-66
Applicability Group
Date 20 August 2002

Guidance on Practice for


Wellhead Control Panels

GP 30-66

BP GROUP
ENGINEERING TECHNICAL PRACTICES
20 August 2002 GP 30-66
Guidance on Practice for Wellhead Control Panels

Foreword

This is the first issue of Engineering Technical Practice (ETP) GP 30-66. This Guidance on Practice
(GP) is based on the BP heritage RPSE document GS 130-12.

Copyright  2002, BP Group. All rights reserved. The information contained in this
document is subject to the terms and conditions of the agreement or contract under which
the document was supplied to the recipient’s organization. None of the information
contained in this document shall be disclosed outside the recipient’s own organization
without the prior written permission of Manager, Standards, BP Group, unless the terms of
such agreement or contract expressly allow.

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Table of Contents
Page
Foreword.......................................................................................................................................... 2
1. Scope...................................................................................................................................... 5
2. Normative references.............................................................................................................. 5
3. Symbols and abbreviations.....................................................................................................5
4. General................................................................................................................................... 6
5. Wellhead control system design..............................................................................................6
5.1. General........................................................................................................................ 6
5.2. Monitoring and controls................................................................................................8
5.3. Shutdown..................................................................................................................... 9
5.4. Materials..................................................................................................................... 10
6. System components.............................................................................................................. 10
7. Hydraulic power unit package...............................................................................................12
7.1. Hydraulic power system design..................................................................................12
7.2. Umbilical hose bundles..............................................................................................13
7.3. System hydraulic analysis..........................................................................................14
8. Testing................................................................................................................................... 14
9. Documentation...................................................................................................................... 15
9.1. General...................................................................................................................... 15
9.2. Supplier proposal.......................................................................................................15
10. Shipping................................................................................................................................ 15
ANNEX A (Informative) Example of an Offshore Wellhead Control Panel
Functional Specification and Data Sheet...............................................................................17
A.1. System description................................................................................................................ 17
A.1.1 General................................................................................................................................. 17
A.1.2 System Layout...................................................................................................................... 17
A.1.3 Shutdown Hierarchy.............................................................................................................. 17
A.1.4 System Performance Requirements......................................................................................17
A.1.5 Operator Interface Arrangement............................................................................................17
A.1.6 Interface with other Systems.................................................................................................17
A.1.7 Special to Project Maintenance Facilities..............................................................................17
A.1.8 Device and Equipment/Panel Tag Numbering.......................................................................17
A.2. Environment, area classification and utilities.........................................................................18
A.2.1. Field equipment.......................................................................................................... 18
A.2.2. Utilities and Services..................................................................................................18
A.3. Data sheet............................................................................................................................. 19
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ANNEX B (Informative) Supplier Documentation............................................................................20


B.1. Documentation required with quotation.................................................................................20
B.2. Documentation required after confirmation of order..............................................................20
B.3. Documentation required prior to factory test..........................................................................20
B.4. Documentation required on delivery......................................................................................21
Bibliography................................................................................................................................... 22

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Guidance on Practice for Wellhead Control Panels

1. Scope

This GP provides guidance for the selection, design, and installation of wellhead control systems
including the wellhead control panel.

The scope of this GP does not include electric wellhead controls.

Electric wellhead control, including electric failsafe actuation of topside wellhead


valves, has been installed on the Andrew facilities (North Sea oil and gas platform).
At this point in time the use of these type of systems are still limited. It is expected
that at a later time when learnings, issues and problems are captured, they will be
incorporated into this document.

2. Normative references

The following normative documents contain requirements that, through reference in this text,
constitute requirements of this technical practice. For dated references, subsequent amendments to, or
revisions of, any of these publications do not apply. However, parties to agreements based on this
technical practice are encouraged to investigate the possibility of applying the most recent editions of
the normative documents indicated below. For undated references, the latest edition of the normative
document referred to applies.

BP
GP 12-15 Guidance on Practice for Wire and Cable.
GP 12-60 Guidance on Practice for Hazardous Area Electrical Installations.
GP 30-25 Guidance on Practice for Field Instruments - General.
GP 30-40 Guidance on Practice for Process Automation Systems.
GP 30-65 Guidance on Practice for Control Panels.
GP 30-80 Guidance on Practice for Safety Instrumented Systems - Implementation.
GP 30-90 Guidance on Practice for Commissioning of Instrumentation and Control
Systems.

International Electrotechnical Commission (IEC)


IEC 60529 Degrees of protection provided by enclosures (IP Code).

National Aerospace Standards (NAS)


NAS 1638 Cleanliness Requirements of Parts Used in Hydraulic Systems.

National Electrical Manufacturers Association (NEMA)


NEMA 250 Enclosures for Electrical Equipment (1000 Volts Maximum).

3. Symbols and abbreviations

For the purpose of this GP, the following symbols and abbreviations apply:

ESD Emergency shut down.

I/O Input/output.

PAS Process automated system.


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PCS Process control system.

PSD Process shut down.

SIS Safety instrumented systems.

4. General

a. For physical design, wiring and general guidelines the wellhead control panels shall
comply with GP 30-65.
b. Design shall meet requirements of appropriate local regulatory authorities.
Example of a local requirement is Code of Federal Regulations (CFR) Title 30,
Part 250, - Mineral Resources, Chapter II, Minerals Management Service, Subpart
H, Oil and Gas Production Safety Systems, Sections 250.800 through 250.807,
Requirements for installations in the Gulf of Mexico (GoM).
Furthermore, in the GoM for offshore platforms, the following standards shall be
complied with as per local regulation:
 API RP 14B Design, Installation, Repair and Operation of Subsurface
Safety Valve Systems.
 API RP 14C Recommended Practice for Analysis, Design, Installation,
and Testing of Basic Surface Safety Systems for Offshore Production
Platforms.
 API RP 14FRecommended Practice for Design, Installation of Electrical
Systems for Offshore Production Platforms.
c. Electrical components and installation in hazardous areas shall be in accordance with
GP 12-60.
d. Instruments and/or systems that are part of the Safety Instrumented System of the facility
shall comply with GP 30-80.
e. Process Automation Systems shall be in accordance with GP 30-40.
f. Testing for instruments and controls shall be in accordance with GP 30-90.
g. Field instruments in general shall comply with GP 12-25.
h. Field mounted equipment shall be IEC IP 66 in accordance with IEC 60529 (NEMA 4X in
accordance with NEMA 250), as a minimum.
i. For topsides located wellhead valves and other duties, excluding subsea, the cleanliness
requirement shall be NAS 8. For any subsea valve applications, the cleanliness
requirement shall be NAS 6. Refer to National Aerospace Standard 1638.
j. Cabling and panel wiring shall be flame retardant to industry standards. Refer to GP 12-15
for general cabling and wiring requirements.
k. To enable uniformity of supply with other equipment, compression fittings shall be subject
to BP approval.

5. Wellhead control system design

5.1. General
a. Wellhead control system should include:
1. Control panels consisting of controls for the hydraulically operated wellhead and
down hole valve actuators for control of single or multiple wells, as required.

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These controls are to permit operation and shutdown of wells from a remote control
system.
2. Facilities for partial or total emergency shutdown from a shutdown system, which
may either be included as part of the wellhead control panel supply, or be part of a
separate system outside the scope of the supplier of the wellhead control panel.
For example, in GOMDW there are three categories of remote I/O modules: Process
Safety System (PSS), Process Control System (PCS), and Emergency Support System
(ESS). These three modules are required for interface with the remote control system
and are purchased, installed, and wired in the electrical portion of the panel as
shown on the project design documents.
3. Hydraulic power unit package consisting of pumps together with hydraulic oil
reservoirs and all necessary controls for multiple pressure levels for operation of the
wellhead and downhole valve actuators. The package may also be required to provide
hydraulic power for additional users such as process emergency shutdown valves.
Pumps could be either pneumatic or electrically driven pumps.
4. Fusible plug loop charge circuitry
b. The wellhead control system shall include equipment failure alarms necessary to ensure
system integrity.
c. Hydraulic supply and control design for multipressure applications shall prevent pressure
buildup when hydraulic demand is zero.
d. The number of pressure levels used in a system should be minimised.
A system that uses a common pressure level with pressure letdown for lower-
pressure applications can cause problems with pressure buildup and erosion of
regulator bleedoff ports. This condition is due to regulator seat leakage when
hydraulic demand is zero.
In the past it was usual to install SSSV hydraulic regulators. Typically reservoir pressures drop and there is a
good commercial case to install lower pressure rated components down hole in later field life, maybe during
a well work over. This invariably means that control line pressures, and hydrostatic head, to new lower rated
SSSV are too high. Solution is to retrofit hydraulic (self relieving) regulator. Consider need for regulator for
SSSV control lines on each well control drawer. Alternatively, allow space on drawer either on back or front.
Or pipe in a dummy regulator, with tubing fittings to facilitate retrofit later. SSSV regulator is also useful for
nursing sick SSSVs, or extending the life of healthy ones as a slowly increasing control line pressure is better
than switching on full pressure. The installation of these regulators may increase maintenance problems and
bring other issues; hence an assessment of their real need is recommended.
e. If multiple pressure levels are required, separate pumped circuits are preferred.
Overpressure, backregulation, or circulating bleedoff may be considered. Tight shutoff
regulators may only be considered as a temporary solution to relieve problems that result
from regulator seat leakage.
f. Pressure-sensing transmitters shall be used in place of pressure switches for alarm and
shutdown activation.
g. Pressure-sensing transmitters shall have test manifolds to facilitate testing.
h. Wellhead control system should be built on a modular basis to allow independent servicing
of individual well controls.
i. Design shall include capability to modify control function, example from a producer well
to a water injection well or vice versa.
j. Potential expansion to accommodate control of additional wells shall be considered in
design.

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Additional panels may have to be added if design does not consider future
expansion.
k. The data highways for the PAS and the SIS system shall be distinct. Routed separately and
redundant for each system.
l. Air supply header shall have redundant filters and regulators with the required piping to
facilitate the replacement or repair of one of the filters or regulators without shutting down
the air supply header.
m. The air supply shall be protected from overpressure if the regulator fails or any other
abnormal condition occurs.
n. Wellhead control panels shall be fully assembled, piped, cabled, and provided with all
necessary lighting, heating, and environmental protection. Assemblies shall provide
connections to be made from readily accessible terminal points.
o. Hydraulic panels shall be provided with drip trays, bunds and panel floor drains.
All hydraulic panels leak, it is important that leakage drains are provided.
p. Cable routes shall be away from sources of leak.
q. Design and layout of equipment shall give free access for maintenance, testing and repair.
Wellhead control panel layouts can be very congested. Access to components and
fittings must be ensured.
r. Repair and routine maintenance shall be possible without total system shutdown, and
facilities lost during any fault repair period shall be minimised.
s. First-line fault repair shall be possible using nonexpert multitrade technicians.

5.2. Monitoring and controls


a. Remote status monitoring should include controls essential for satisfactory production
operations or shutdown.
b. As a minimum, the following status indicators should be included:
1. Hydraulic pressure for each hydraulically actuated valve.
2. Hydraulic pressure for each individual supply header.
3. Each valve position.
4. Each wellhead temperature and pressure.
c. Modules may have requirements for local control and remote control.
d. Remote control of functions other than shutdown shall be considered.
Remote operation is essential for minimisation of manning; when fast response is
required an/or local control is not practical.
e. For remote operations proper diagnostics and pertinent process conditions shall be
provided.
This is critical if remote start up is considered.
f. An operator interface terminal may be mounted on the panel door to facilitate required
testing.
g. Pressure indications of remote status monitoring controls shall be displayed also by gauges
on the wellhead panel.
h. If applicable, choke control and position indication should be via the facility Process
Automated System (PAS).

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5.3. Shutdown
a. Wellhead shutdown design shall be failsafe.
Fail safe, i.e., de-energised, depressurised, contacts open to trip.
b. Wellhead valves shall be failsafe spring action to close.
c. Remote shutdown is allowed.
d. Shutdown initiation from central control facilities or from separate shutdown systems shall
be hardwired with the following components:
1. Control devices shall be 24Vdc, powered from a remote control system.
2. Solenoids shall be 24Vdc, low power, high temperature moulded coil with stainless
steel body and fittings.
e. Voltages specified for solenoid valves shall account for cable voltage drops.
f. The design of the wellhead controls shall be such that shutdown bypasses any control logic
incorporated into the panel while retaining wellhead valve closure timing.
There are often problems with valve closure times. This may result in the installation
of large bore hydraulic return lines mainly for critical offshore applications.
g. Shutdown design shall include the following:
1. Controls shall permit local or manual control and remote control of each well surface
safety valve.
2. The opening and closing sequence of the well control valves, subsurface, surface, and
wing, shall be provided by the shutdown system.
h. Unless facilities are unmanned, ESD shutdown shall require emergency shutdown (ESD)
reset at the wellhead panel.
i. Shutdown level requirements shall be detailed, to include at least the following three
levels:
1. ESD or Fire: All wing, surface, and subsurface valves are closed.
2. Process shutdown (PSD): All wing and surface valves are closed.
3. Individual Well Shutdown: Selected well wing and surface valves are closed.
j. Controls shall include wellhead shutdown valve sequence timing facilities to ensure
closure of valves in the following sequence:
1. Wing.
2. Master.
3. Downhole safety.
Such timing should ensure that closure of subsequent valves is not inhibited if the
timing device fails.
k. Controls shall also include wellhead opening valve sequence timing facilities to ensure
opening of valves in the following sequence:
1. Downhole safety.
2. Master.
3. Wing.
l. Control shall also include an “Out of Sequence” override.

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This overrides the normal enforced sequencing and is particularly useful for
managing handover of wells from operations to well services and vice versa.
m. The opening and closing of all automated valves shall have adjustable speed control
devices built into the valve actuator control circuits.
This minimises the hydraulic ram effect that results from quickly opening and
closing valves.
n. If required, key protected inhibit facilities shall be provided, as necessary, to enable routine
testing of the system, inputs, and outputs. All inhibits shall be reported to the central
control equipment and indication shall not be cancelled until the inhibit has been removed.
Keys shall be retained in the defeat position.
Provision of test facilities can result in system complexity and cost but it does
minimize testing time.

5.4. Materials
a. Materials of construction shall be suitable for the service and the environment where the
system is located.
b. For offshore applications, AISI 316 stainless steel is preferred for items such as control
panels, cable tray, and cladding.
c. Stainless steel is recommended for hydraulic reservoirs and pipework. If material other
than stainless steel is proposed, alternative selection shall be justified.
Stainless steel ensures system cleanliness.

6. System components

The wellhead control system may not require all the components listed below. Each
wellhead installation requirement should be evaluated based on project specifics.
Important elements include the ability to shut down a well quickly and safely to
avoid endangerment of personnel, and without the risk of polluting the environment.
a. A horn and strobe suitable for outdoor installation in a classified area should be installed
on top of the panel. The horn and strobe shall be activated when any alarm or shutdown set
point is achieved.
The horn volume and strobe colour should be specified as per the local facility requirements.
b. Bulkhead fittings for the hydraulic connections between the wellhead control panel and the
wellheads.
c. The following front panel mounted controls/indicators may be considered for each well:
1. Manual 3-way valve for each well shutoff valve (subsurface valve, surface safety
valve, and wing valve) to allow local manual closing and lockout of each individual
well.
2. Hydraulic line pressure gauges for each automated well shutoff valve.
d. The following non-front of panel devices may be considered for each well:
1. Pressure transmitters for hydraulic supply to each automated well shutoff valve.
2. System common 3-way solenoid valves and 3-way air-operated hydraulic valves for
each automated well shutoff valve.
3. Hydraulic pressure relief valves for supply to each automated well shutoff valve.
4. Needle valves for hydraulic supply and return of each subsurface automated shutoff
valve.
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5. Block and check valves for hydraulic supply to each automated well shutoff valve.
6. Flow line pressure safety transmitters for each segment of each well, including any
required testing accessories.
e. Other devices that may be considered to be on the front panel are:
1. Push to hold to test ESD solenoid.
2. Pressure gauge for indication of the ESD solenoid outlet pressure.
3. Pressure gauge for indication of the panel air supply pressure.
4. Pressure gauge for indication of the regulated panel supply pressure.
5. A 3-way test valve for the fusible plug loop pressure transmitter.
6. “Push to Charge” push button for fusible plug loop.
7. Pressure gauge for indication of the wellhead fusible plug loop pressure.
8. Air regulator for the subsurface valve hydraulic pump.
9. Air regulator for the surface safety valve hydraulic pump.
10. Air regulator for the wing valve hydraulic pump.
11. Selector valve for the normal pump/spare pump for the high pressure subsurface
safety valve.
12. Selector valve for the normal pump/spare pump for the intermediate pressure
subsurface safety valve.
13. Selector valve for the normal pump/spare pump for the surface safety valves.
14. Selector valve for test/spare pump.
15. Pressure gauge for indication of the hydraulic pump air supply pressure for the high
pressure subsurface valve.
16. Pressure gauge for indication of the hydraulic pump air supply pressure for the
intermediate pressure subsurface safety valve.
17. Pressure gauge for indication of the hydraulic pump air supply pressure for the
subsurface safety valves.
18. Pressure gauge for indication of the hydraulic pump output pressure for the
subsurface valve.
19. Pressure gauge for indication of the hydraulic pump output pressure for the surface
valve.
20. Pressure gauge for indication of the hydraulic pump output pressure for the wing
valve.
21. Air regulator for the test/spare pump.
22. Pressure gauge for the test/spare pump pressure indication.
23. Pressure gauge for the test/spare pump output pressure indication.
24. ESD push button.
25. PSD push button.
26. Pressure gauge for indication of the upstream segment flow line pressure for each well.
27. Pressure gauge for indication of the downstream segment flow line pressure for each well.
28. Manual 3-way valve for each flowline segment transmitter test.

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29. Quick disconnects for each pressure test circuit.


f. In addition to the above panel located devices, I/O may need to be provided for the
following additional signals for each well as required:
1. Well tubing pressure.
2. Well casing pressure.
3. Flow line temperature.
4. Choke valve position.
5. Choke valve control.

7. Hydraulic power unit package

7.1. Hydraulic power system design


a. Proposed pumping method shall provide optimum solution for cost and reliability.
There may be restrictions on particular applications with regard to availability and
reliability of supply. This may dictate that either air pumps, electric pumps, or
combinations should be used.
b. Minimum accumulator capacity shall as a minimum:
1. Allow opening of all valves on one wellhead while retaining supply header pressure
above minimum, independent of pump recharge action.
2. Prevent frequent cycling of hydraulic pumps due to system component leakage.
A minimum of two accumulators for each pumped pressure level are necessary to
allow for maintenance. Calculation of accumulator capacity should take into
account the adiabatic nature of the accumulator volume displacement.
c. Accumulators shall be provided with pre-charge facilities, complete with required bottled
gas, booster pumps, and all interconnecting piping, valves, and fittings.
Permanently installed facilities may not be necessary if wellheads are spread out
and independent small wellhead control packages are involved, such as with
onshore installations. For these installations, a portable unit for many systems may
be appropriate. For wellhead clusters such as experienced offshore, a permanently
installed facility is more appropriate.
d. Pump recharge rate shall allow opening of the number of wellheads within a specified
time. Alternative rate as an option may be proposed if significant cost savings can be
achieved with reduced performance consistent with systems previously supplied.
The rate of opening of wellheads needs to be realistic. An excessive requirement can have unnecessary cost
implications. The rate should be agreed with operations and should be consistent with the need for physical
monitoring of opened wells for leakage before proceeding with further well operation. A maximum
frequency of opening one well every three minutes is considered realistic. A similar basis for returning to
production after routine shutdown, with wing valve only closing, is also considered appropriate when
considered with the need for resetting chokes.
e. Reservoir shall be such that the capacity to minimum level includes total system, supply
line and actuator volume, return tank volume to high level alarm, plus a contingency to
allow for accumulator loss of pre-charge and leakage.
A contingency of about 10% should be adequate for most applications.
f. Details of the reservoir system are required and any application specific special
requirements shall also be detailed.

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g. Two threaded DN 15 (NPS 1/2) connections with isolation valves for periodic, manual,
high level filtration using external equipment shall be provided. One of these connections
shall also serve as a sampling point.
h. A threaded DN 25 (NPS 1) drain connection shall be provided to the outside of the
hydraulic panel section.
i. Continuous signals shall be provided for hydraulic pressure and reservoir level.
j. Each supply line to the hydraulically actuated valves shall have a check valve installed as
close as feasible to the actuator, upstream of the solenoid valve.
This will allow maintenance on the hydraulic system upstream of the actuator
without changing the valve position.
k. Each hydraulic supply line shall have a panel-mounted pressure gauge.
This gauge serves as a valve position indicator.
l. A separate return tank with vent for entrained gas shall be provided for return from
downhole safety valves. Means shall be provided for test of return tank contents and
filtered return to the main reservoir as well as dumping contaminated oil to drain or barrel.
Tank shall be sized to permit two closing operations of all valves before reaching high
alarm level.
Consideration should be given to the possibility of contamination of hydraulic fluid
from other users.
m. The recommended hydraulic fluid shall be demonstrated to be suitabile for the application.
Suitability shall be based on downhole and ambient temperatures considering fluid
degradation and the viscosity necessary for operation.
n. The following front panel mounted controls or indicators may be considered for common
systems:
1. Hydraulic pressure gauges for each hydraulic pressure supply header.
2. Air pressure regulator for each air operated hydraulic pump.
3. Operator interface terminal to facilitate required testing.
o. The following minimum non-front mounted panel devices may be considered for the
common hydraulic system:
1. Redundant air supply filters, valves, and pressure gauges.
2. Air pressure regulator, pressure gauge, and pressure transmitter for each regulated air
pressure circuit.
3. Safety pressure relief valves as required to prevent system overpressure in any
abnormal condition.
4. Hydraulic pressure transmitter for each hydraulic pressure circuit.
5. Hydraulic reservoir level transmitter.
6. ESD solenoid valve (and associated pilot valves) to stop hydraulic pumps.
7. Hydraulic test pump with all associated devices to allow testing of hydraulic pressure
transmitters. This pump should also be installed as a standby spare for each of the
other pumps.

7.2. Umbilical hose bundles


a. Umbilicals shall be used for connection of hydraulic control and return between wellhead
control panel and wellheads.

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Umbilicals are most suitable for multiple wellhead installations where hard piping
is difficult and expensive. Umbilicals for small or simple installations may be
inappropriate.
b. Multitube umbilical hose bundle design shall:
1. Be suitable for operating pressures and temperatures and sheathed overall to provide
protection from the installed environment, risk of impact damage, and fire resistance.
2. Maintain flexibility without flattening for installation purposes.
3. Have a minimum service life of 20 years.
Need for armour depends on method of installation. Umbilicals may be subject to
oil spills and specification of outer sheath shall account for this.
It may be more cost effective to accept the Vendor recommended umbilical and have
stringent periodic maintenance testing procedures to assure safety and reliability. It
seems likely that periodic testing would be required even if “20 year” umbilicals
were used.
c. Individual hydraulic hoses within the umbilicals shall be sized to ensure that closure of
wellhead valves is achieved within specified times.
d. Umbilicals shall include all connectors, mounting plates, and individual hoses for
connection and reconnection to wellhead panel and individual wellhead valves.

7.3. System hydraulic analysis


a. A fully detailed dynamic hydraulic analysis of wellhead control system to confirm
operation capability shall be provided. Analysis shall include all components within the
system, including:
1. Pipework.
2. Umbilicals.
3. Drain lines.
4. Fittings.
5. Actuators.
6. Hydraulic power unit.
7. Wellhead control panel.
This analysis is necessary to ensure elements of the system do not cause restrictions
and resultant delays in valve operation times.
b. A failure modes effects analysis of the system, considering the consequences of any single
component failure shall be performed. This analysis shall be used to demonstrate that a
single common mode failure does not jeopardise the integrity of the system and it is not
revealed.
c. Shortfalls in design found as a result of system analysis shall be rectified before factory
system test.

8. Testing

a. Detailed test procedures shall be produced to demonstrate design integrity along with
correct operation of each element of the total wellhead control system.
b. Tests shall be performed with simulated interconnecting pipework and drain lines
connected, which provide equivalent restriction and pressure drop.

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c. System test shall include demonstration of satisfactory operation of wellhead valves by


either actual project wellhead setup, or simulation with equivalent operating conditions,
back pressures, and swept volumes.
d. Test procedure shall ensure that on-site testing and remedial work is minimised. Testing
shall be recorded and records retained for inspection and audit purposes.
e. Electronic controls shall be demonstrated to be immune to electromagnetic interference by
using project specific sources for test purposes.

9. Documentation

9.1. General
a. Documentation shall be provided to enable assessment of design.
b. Documentation shall be limited to that essential to verify conformance with specified
functionality and as necessary to permit installation, operation, calibration, and
maintenance of the system.
c. Documentation requirement should be detailed in the Functional Specification.

9.2. Supplier proposal


a. Supplier shall submit proposal for preferred arrangement to enable functions to be
performed.
b. Proposal shall have full justification to demonstrate:
1. Optimum life of field costs.
2. System performance.
3. Availability.
4. Minimal maintenance requirements.
It is essential that agreement with BP is achieved during the initial design phase
regarding the required operating and maintenance philosophy.
c. Supplier shall provide estimated weight and centre of gravity with proposal. The design
weight and centre of gravity with the approved for construction drawings, and the actual
weight and centre of gravity with the “As Built” drawings. See annex B for typical supplier
documentation requirements.
Specific documentation requirements need to be defined for each particular
application.
The prime objective is to eliminate unnecessary documentation, reformatting, and
approvals, thereby realizing large savings in vendor and contractor costs.

10. Shipping

a. Each panel shall be cleaned, secured, protected, and packaged in a weatherproof enclosure.
Additional shipping preparation for ocean shipping to an offshore platform may be
required.
b. Cabinet internals shall contain packets of desiccant to adequately protect moisture sensitive
items and electrical connections.
c. Package crating and weather protection shall be adequate for storage for six months prior
to installation.

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Weather protection includes wind, rain, salt spray, and sun as applicable.
d. Prior to packaging, external system connections such as pipe, tubing, and conduit shall be
plugged, using devices specifically intended and manufactured for these purposes.

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ANNEX A
(Informative)
Example of an Offshore Wellhead Control Panel
Functional Specification and Data Sheet

A.1. System description

A.1.1 General

(Note: Description of the project, location and application.)

A.1.2 System Layout

(Note: Summary of the required system, equipment component


split and layout, any remote control.)

A.1.3 Shutdown Hierarchy

(Note: Summary of required shutdown levels and how these are to


be initiated and controlled. Include any 'hard wired'
shutdown requirements. The amount of shutdown logic to
be incorporated within the wellhead control system should
also be detailed with due regard to well head control and
requirements for submersible pumps, where installed. Use
of main platform shutdown systems, where provided, for
these functions is preferred.)

A.1.4 System Performance Requirements

(Note: Include requirements for no of wells to be opened within


time scale and subsequent recharge.)

A.1.5 Operator Interface Arrangement

(Note: Detail required controls for remote and local operation.)

A.1.6 Interface with other Systems

(Note: Include details of the interfaces with other systems for


control, shutdown, alarm and status monitoring. Any
requirements for additional status and control signals not
associated directly with wellhead operation, should also be
detailed here.)

A.1.7 Special to Project Maintenance Facilities

(Note: Agree any special requirements with the operator.)

A.1.8 Device and Equipment/Panel Tag Numbering.

(Note: Detail to fit with project philosophy.)

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A.2. Environment, area classification and utilities

A.2.1. Field equipment


Field equipment will be subjected to a marine environment with a salt laden atmosphere.
Max. ambient temperature °C
Min. ambient temperature °C
Max. Rel. Humidity %
Area Classification Zone
Gas Group II
Temperature Class T
Central control/Field equipment rooms
The control/equipment rooms shall be classified as a safe area and suitable for general-purpose
equipment such as control panels and printers.
Max. ambient temperature °C
Min. ambient temperature °C
Max. Rel. Humidity %

A.2.2. Utilities and Services


Electrical power
1. Voltage V AC V AC
Frequency Hz Hz
Regulation - VTA
Harmonic Distortion - VTA
Switching Transients - VTA
2 Voltage V DC V DC
Regulation - VTA
Ripple - VTA
Harmonic Distortion - VTA
Instrument Air
Inst. Air Pressure barg. (max.) barg. (min.)
Dew Point °C
Plant Air
Air Pressure barg (max.) barg. (min.)
Dew Point °C
VTA - Vendor to advise with submission

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A.3. Data sheet

WELLHEAD CONTROL PANEL

No. of Wellheads
Valves Wing Master Downhole Other
Control Local (o/c)
Remote (o/c)
Status Local (o/c)
Remote (o/c)
Shutdown Level
Stroke Volume
Closure Time (max.)
Sequence Time
Actuator Pressure
(max./min. barg)
Panel Environment

WELLHEAD HYDRAULIC POWER PACK

Initial Charge Time VTA


Wells Open Time
Recharge Time VTA
Accumulator Capacity VTA
Reservoir Capacity VTA
Downhole Temperature
Hydraulic Oil VTA
DHSV Clean-up System
Wellhead Service Unit
System Test Facilities
Package Environment
System Alarms VTA

WELLHEAD CONTROL UMBILICALS

Lengths: Wellhead control panel to wellhead:


Well No:
Length:

Well No:
Length:

Well No:
Length:

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ANNEX B
(Informative)
Supplier Documentation

B.1. Documentation required with quotation

As a minimum the documentation listed below shall be provided with quotation:


a. Detailed description of proposed system.
b. List of applicable codes and standards, and any deviations from these or this specification
and associated documentation.
c. Accumulator and reservoir sizing and basis.
d. Hydraulic oil proposals.
e. Statement of capabilities and proposals for providing installation supervision (onshore or
offshore) and testing and commissioning (onshore or offshore).
f. Details of proposals for failure modes and effects analysis, and dynamic hydraulic
analysis.
g. Proposal for construction, testing, and delivery.
h. Proposals for testing and commissioning.
i. Spares and test equipment proposals together with prices.

B.2. Documentation required after confirmation of order

As a minimum the documentation listed below shall be provided after confirmation of order:
a. Front of panel layout drawings.
b. Logic diagrams (hydraulic, pneumatic, and electrical).
c. Equipment utility load estimates.
d. Wiring, electrical distribution, grounding, and interconnection drawings.
e. Installation and terminal point details.
f. Equipment lists, schedules, and data sheets for input to operational maintenance database
systems, if specified.
g. Interface schedules including signal state.
h. Detailed spares and test equipment listings to cover commissioning and two year
operation.

B.3. Documentation required prior to factory test

As a minimum the documentation listed below shall be provided prior to factory test:
a. Detailed procedure, program, and test sheets for system testing at the factory, on site
commissioning, and subsequent routine operation and maintenance. These are to include
the system, any subvendors, and any ancillary equipment.
b. Failure mode and effects analysis with corrective actions taken.
c. Dynamic hydraulic analysis with corrective actions taken.
d. Equipment safety certification dossier (as applicable).
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e. Operation and maintenance manuals with all information necessary for continued
operation during the life of the installation.
f. Listing of all control and trip settings.

B.4. Documentation required on delivery

As a minimum the documentation listed below shall be provided on delivery:


a. As-built of all documentation listed.
b. Actual weight and centre of gravity shall be provided with as-built drawings.

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Bibliography

American Petroleum Institute (API)


[1] API RP 14B, Design, Installation, Repair and Operation of Subsurface Safety Valve Systems

[2] API RP 14C, Recommended Practice for Analysis, Design, Installation, and Testing of Basic Surface
Safety Systems for Offshore Production Platforms

[3] API RP 14F, Recommended Practice for Design, Installation of Electrical Systems for Offshore
Production Platforms

American Society for Testing and Materials (ASTM)


[4] ASTM 1166, Standard Practice for Human Engineering Design for Marine Systems, Equipment and
Facilities

Code of Federal Regulations (CFR)


[5] Title 30 CFR Part 250, - Mineral Resources, Chapter II, Minerals Management Service, Subpart H,
Oil and Gas Production Safety Systems, Sections 250.800 through 250.807

National Electrical Manufacturers Association (NEMA)


[6] NEMA ICS 6, Enclosures for Industrial Controls and Systems

National Fire Protection Association (NFPA)


[7] NFPA 70, National Electrical Code, Volume Three of National Fire Codes

[8] NFPA 496, Purged and Pressurized Enclosures for Electrical Equipment

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