SURFACE WELL COMPLETION

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Basic training operator Oil & gas Advisafe Risk Management B.V.

Copyright Advisafe Risk Management B.V.

Version 1.0
All rights reserved. No part of this publication may be duplicated, stored in a computerised
database, or disclosed in any form or any way, either electronically, mechanically, by
means of photocopies, recordings or any other way whatsoever, without prior written
consent from Advisafe Risk Management B.V.

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 Content
1. Casinghead-housing and spools ............................................. 5
1.1. Summary of surface well completion .......................................................... 5
1.2. Casing head housing and spools ................................................................ 7
1.3. The Cameron CA casing hanger ................................................................. 9
1.4. The Cameron BRX type 2 casing hanger .................................................. 11
1.5. X-bushing with P-seal ................................................................................ 12

2. Tubingheads and metal seals ................................................ 14

2.1. Summary of tubing heads and metal seal .................................................. 14

3. Tubingheads and metal seal ................................................. 16

3.1. LDO tubing head ....................................................................................... 16
3.2. SRT tubing head ........................................................................................ 17
3.3. Metal seal....................................................................................................20
3.4. Boll-weevil tubing head ............................................................................. 21

4. Christmas-tree ....................................................................... 23
4.1. Summary of the Christmas-tree .................................................................23
4.2. The solid block Christmas tree ..................................................................24
4.3. The components of the composite Xmas tree ...........................................26
4.4. The Xmas tree for the production cross for gas lift oil wells .....................28
4.5. The Xmas tree setup on clusters ................................................................29

5. Gate valves ............................................................................. 31

5.1. Summary of Gate valves ............................................................................. 31
5.2. The principle structure of a gate valve ....................................................... 31
5.3. Requirements set for valves .......................................................................32
5.4. The method of sealing gate valves .............................................................33
5.5. Sealing compound method ........................................................................33
5.6. The McEvoy gate valve, model C ..............................................................35
5.7. The Cameron gate valve, type F ................................................................36

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1. Casinghead-housing and spools

1.1. Summary of surface well completion

The functions of the surface well completion are:
hanging the successive casings and sealing them off from one another and the
surrounding area;
providing the option of shutting down well production;
providing the option of making observations and having controlled access to the
well for various activities.

The completion consists of the following components:

Casing head housing

Casing head spools
Tubing head
Christmas tree

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 5 1/8 API 5000 type
F solid-block tree

6 double P seal

Check port Plastic packing ports

Metal seal
Intermediate flange

SRT tubing head

10 x 6 API 5000
control head

Tubing hanger
nippel

7 5/8 double P seal

Check port
Plastic packing ports

Casinghead spool CA slip and seal assembly

16 API 3000 x 10 x 7 5/8
10 API 5000
Casinghead type WF
x-busing 16 x 10 o.d.
casing

CA slip and seal assembly

16 x 10
Check port

Casinghead housing
16 API 3000 x
Casinghead type WF

16 casing

10 3/4" casing

7 5/8 casing

5 1/2 casing

Overview surface well completion

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1.2. Casing head housing and spools

The casing head housing is screwed (and sometimes welded) on top of the conductor and
serves to:
anchor the blowout preventer to the first casing stack during drilling;
support the above-ground well completion;
support the next, smaller casing stack via the casing head spool and the casing
hangers;
seal the annular space between the two largest casing stacks;ensure access to the
annulus

The casing head

housing is installed on
the casing (see figure).
Tubing head spool
There is a flange
Test channel connection on top, on
which the casing head
10 casing outlet spool will be mounted
at a later stage.
16x10 casing
head spool
The housing has two 3
drain holes opposite
BRX type 2
each other, with
Casing hanger
flanges threaded on the
inside. The annulus
x-bushing shut-off valves are
attached to this in
16 casing outlet order to enable mud
circulation.
Injection channel On the inside, the
Tubing 5 1/2" casing head housing is
a bore that is partially
16 casing outlet straight and partially
tapered.
Tubing 5 1/ 2

Annulus 5 1/2 x 7 3/4

Casing 7 3/4

Annulus 5 1/2 x 10 3/4

Casing 10 3/4"

Annulus 10 3/4 x 16

Conductor 16

Casing head housing and casing head spools

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The first casing head spool is connected to the casing head housing by means of a
flange fitted with a metallic packing (ring joint). The number of casing head spools
depends on the number of casing stacks with which the well is equipped. In the case
of the figure above, only two casing stacks (the 10 and 7 casings) are taken in,
in addition to the 16 conductor, and only one casing head spool is used. The spool
connects the various flanges with reduced diameters, which correspond with various
consecutive casing stacks.

The spool consists of a housing with a conical notch for the casing hanger at the top.
When the
Cameron CA casing hanger is used, there is space for the X-bushing with P-seal in
the lower flange. A filling and test port for the P-seal are also installed in the lower
flange. When the Cameron BRX casing hanger is used there are two filling ports
and two test ports in the lower flange. Two ports with thread and flanges in the side
wall of the housing provide access to the annular space.

Valves are installed on the side flanges of the casing head housing and casing head
spools. These valves provide access to the annular spaces to measure the pressure or,
if necessary, to vent the pressures accumulated.
The tubing head spool is installed on the top flange of the top casing head spool, in
which the tubing is hung.

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1.3. The Cameron CA casing hanger

After a casing stack is inserted at depth, the string with slips is hung from the rotary table.
The casing hanger is installed around the pipe. The casing, with the casing hanger around
it, is lifted with the hoisting facility and passes through the hole in the rotary table and the
BOP stack to the desirable depth, after which the casing hanger is secured.
The hanging system consists of two slips (components that enclose a flexible packing
component) and is called slip and seal assembly.

16 casinghead housing

Slip A

Slip C

Seal

Slip D

Slip B

10 3/4" casing

Cameron CA casing hanger with slip and seal assembly

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The whole packet is pressed together and kept together by long threaded bolts. By
hanging it the serrated slips are pushed against the outside of the casing. Slip D drags
against the conical inside wall of the casing head housing and ensures the hanging
process. The flexible packing component is pressed against the wall laterally and forms a
seal between the two successive casing stacks.

An advantage of the CA hanger system is that the hanger drops to the desirable level
around the casing and catches at the place with the serrated slips.

The disadvantages are:

The casing hanger is not installed until the casing head housing or spool is
attached. In practice the hanger is placed through the BOP with the risk that the
hanger will get stuck or drag to a halt in the BOP.
The 'slip and seal assembly' often leaks, while the additional seal formed by the X-
bushing with single P-seal is also inadequate.

To eliminate these disadvantages, a Cameron modified BPX hanger was developed, which,
working in collaboration with Cameron, resulted in the BRX type 2 casing hanger.

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1.4. The Cameron BRX type 2 casing hanger

This hanger is likewise used in a casing head housing as well as in a casing head spool.

Injection port

P-seal

Casing head spool

Test port

Ring joing

16 casing head housing

Ring joint

BRX hanger

10 3/4 casing

Cameron BRX type 2 casing hanger

The conical casing hanger is screwed to the last casing pipe, which must be cut off at a
length accurately specified in advance and threaded. All this is lowered into the well from a
running tool which is screwed into the top of the casing hanger, till the conical section
drags against the conical support in the casing head spool. Dropping is a lot easier through
the BOP than with the slip and seal assembly.

The BRX hanger and the conical support of the casing head housing/spool both have a
smooth finish. The seal is obtained by two canvas seal rings in the BRX hanger. The BRX
type 2 hanger is tapped with a left-hand thread into which the running tool can be
screwed. After shut off, the running tool is unscrewed. At a later stage, the polished
surface right above the left-hand thread can be sealed with a double P-seal.

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The advantages of the hanger are:
improved control of casing hanging through the BOP.
better sealing systems.

1.5. X-bushing with P-seal

The purpose of the X-bushing with P-seal is to provide additional sealing in the casing
hanging (for CA casing hangers, see figure on the left).

The X-bushing with P-seal

is enclosed in a chamber
bored at the bottom of
the casing head spool.
Tubinghead spool
The seal by the P-seal can
be servo-assisted via an
Test channel
injection port in the
Casing hanger flange and inspected via a
test port. The X-bushing
Casinghead spool is a metal, ring-shaped
component that is slid
over the cut-off casing
X-bushing
end and is locked into the
chamber bored into the
casing head spool above.
Injection channel

Casing hanger

Casinghead housing

Casing head spool

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 The seal between the
housing of the casing head
X-bushing spool and the outside
P-seal circumference of the X-
bushing is obtained by two l-
Casinghead spool Non-return valve shaped seal rings in the
Injection channel outside circumference of the
X-bushing.
1/2 test port Pressure plug
The seal between the casing
Non return valve Bleeder plug and the X-bushing on the
Shut-off cap inside is obtained by a
Ring Joint canvas ring in the inside
16casinghead Profile RX
housing housing circumference of the X-
bushing. This packing ring
L-seal can be activated via an
injection port with plastic
packing material, whereby
the P-seal comes in contact
with the casing.
10 3 /4 casing

X-bushing met P-seal

The sealed-off space between the X-bushing ring joint and the casing hanger is pressure
tested via a test port and checked for leakage through the P-seal.
Only one P-seal is used for the X-bushing, which was found to be a shortcoming.
Nowadays a different type of casing hanging is used, with a double P-seal as a seal above
it. If one leaks, a good seal can still be obtained with the other P-seal.

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 2. Tubingheads and metal seals

2.1. Summary of tubing heads and metal seal

The tubing is connected in the bottom of the well to the packer, which seals the casing and
the tubing. The connection between the tubing and the annulus must also be sealed at the
top, meaning above-ground. The total weight of the tubing string must also be absorbed,
which is dealt with by the tubing head spool and the tubing hanger nipple connected to the
tubing.

5 1/8 API 5000 type F The tubing head spool is a

6 Solid-block tree
double P seal
transition from the
narrowest casing to the
Check port Plastic packing ports Xmas tree or to a
Metal seal Plastic packing ports
temporary adapter.
Internally, the tubing
head spool is processed in
such a way that the
tubing hangs in it with
SRT tubing head
10 x 6 API 5000
tubing hanger nipple and
conrol head seals it. The method of
hanging depends to a
Tubing-hanger
large extent on the
nippel temperature of the
medium flowing through
during production. Tubing
7 5/8 double P seal is hung without
prestressing in cold
Plastic packing ports
Check port shallow wells.
Casing spool In deep wells, large
CA slip and seal
16 API 3000 x
assembly 10 x 7 5/8
differences in length can
10 5000 be created between the
Casinghead type WF
X-bushing 16 x 10 3/4 cold, enclosed well and
o.d. casing the warm producing well.
In such wells the tubing is
Plastic packing ports prestressed before
Check port hanging, which means
Casinghead housing
installed in the cold well
CA slip and seal
16 API 3000 assembly 16: x 10 3/4" after prestressing.
Casinghead type WF

16 casing

10 3/4 casing

7 5/8 casing
Surface well completion
5 1/2 casing

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As soon as the temperature of the well increases during production, this prestress
disappears for the most part due to expansion of the tubing material. However, enough
tensile strength will be left in the tubing for it to seal properly and not buckle, which would
cause production or wireline problems. The following tubing heads are mostly used:
LDO tubing head
SRT tubing head
Boll-weevil tubing head

LDO and SRT tubing head is used in gas wells, in which the tubing is prestressed before
hanging in order to ensure that the tubing will always be stressed when hanging at
temperature differences. A boll-weevil tubing head is used for oil wells and injection, wells
in which the tubing hangs free in the centre of the casing.

A plug can be installed in the tubing hanger nipple for all three systems, thereby
protecting the well from fluid or gas flowing out during an exchange in completion above-
ground or when a blowout preventer (BOP) is installed. The above-ground completion can
also be pressure tested using this plug after installation or exchanges.

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 3. Tubingheads and metal seal

3.1. LDO tubing head

This head is installed on the top casing head spool.

Production cross
Tubing hanger -nippel

plastic or P-seal injection ports

Soft metal seal ring (metal seal)

Control of test ports

Intermediate flange
for metal seal
Ring joint

Body of LDO head

Body of LDO head

Conductor pin

V-packingset cover with

packed spindle (2x)
plastic or P-seal injection
ports with bleeder plugs Seal check with bleeder
plugs
Bleeder plugs

Casinghead spool

LDO head

The tubing is hung from the rams in the tubing head spool. The tubing hanger nipple,
which is attached to the tubing, is used for this purpose. A packing is installed in the rams
to ensure sealing on the polished surface of this nipple and the LDO head. The tubing is
hung by closing the rams around the polished section of the tubing hanger nipple so the
front of it rests on the rams.

The rams are opened and closed by screw spindles. One must pay attention that the
tubing hanger nipple is centred as accurately as possible. The rams are fitted with rubber

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 seals which ensure that by tightening the spindles and the weight of the tubing a proper
seal between the tubing and the casing is obtained.

The tubing hanger nipple is threaded on both sides and has a landing nipple profile on the
inside so it can shut off a plug by means of wireline.

3.2. SRT tubing head

Nowadays so-called tension heads, type Cameron SRT, are installed in new gas wells. Also,
the LDO heads used before are now often replaced with SRT heads during a workover. This
tubing head is also installed on the top most casing head spool.

Production cross

Plastic injection port

Metal seal with controlport

Intermediate flange

Packing securing bolts

Packingset

Body

Ledge cover

Ledge cover

Stops of centring the tubing hanger

Controlof test port

Controlof test port

Ring joint

Cameron SRT tension head

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Just as it is for the LDO head, the tubing is hung on the rams here by means of a polished
tubing hanger nipple provided with internal notches so that plugs can be shut off.

The advantages over LDO heads are:

The rams only serve to hang the tubing in a central position, thus not to seal it.
Because the rams drag to a halt on a stop, we know for a fact that the tubing
hanger is in the centre after the rams have been screwed in completely.
A separate packing bushing (sandwich seal) ensures sealing. If there are any leaks,
plastic can still be injected to thereby rectify the leaks.
A workover mast is no longer required should the packing need to be changed,
because the tubing hanger nipple continues to hang on the rams.

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 Access to the annulus
Plugged The tubing head housing has two openings on
the side through which a connection with the
annulus can be established. A set of double
valves are installed in either opening. Via one
set of valves, which are sealed in the open
position, the kill pump line is connected from
the kill pump manifold to the annulus so that
the well can be killed at any time.
A non-return valve is installed in the kill
pump to prevent the pipe and the manifold
from being subject to the full well pressure in
case of a leak between the tubing and the
annulus. The servo-condensate mixture that
Metal seal
serves to combat the corrosion of the tubing
by CO is also pumped into the annulus via
these valves. The annulus is filled entirely
with servo-condensate and can be injected
into the tubing via the injection valve in the
Connection for hydraulic bottom most SPM. This is accomplished by
inspection
pumping the servo-condensate into the
annulus by means of a membrane pump.
The valves on the additional side openings to
the annulus are closed. An inspection port is
Tubing hanger nippel sometimes installed here.

SC SSV control line

Nowadays the control line to the SC SSV
usually runs via the metal seal through the
wall of the tubing hanger nipple and
thereafter to the safety valve via the annulus.
Control line to ball valve
The purpose of the control line is to operate
the SC SSV hydraulically.

Detail of SC-SSV hydraulic control line

though the wall of the SRT tubing hanger nipple

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 3.3. Metal seal
The metal seal for the hanger nipple is the most important seal between the tubing and
the annulus. The seal consists of a soft metal ring, which is butted up against the tubing
hanger nipple between the Christmas tree and the flange beneath it.

An inspection or test port of the

space between the tubing
Flange of composite
production cross. hanger nipple and the soft
Tubing-hanger-nippel metal ring provides indications
on possible leakage through
Intermediate flange, Control of testport
specially installed for
the inside. Leakage passing
the soft metal ring the soft metal ring on the
seal. outside must be detected by
Plastic injection port listening for air passing or
P-seals using a gas detector. This test
Metal seal port is also used as a passage
Ring joint for the hydraulic control
pressure for the underground
Packing securing safety valve (SC SSV).
bolts
However, not one leak has
been detected during 10 years
of experience with metal seals.
Intermediate flange
specially installed for Leakage along the plastic seals
the soft metal ring (P-seals) in the Christmas tree
seal. can be rectified by injecting
more plastic. This seal only
serves to prevent corrosive
fluid from the tubing from
corroding the metal seal.

Seal around the tubing hanger nipple

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3.4. Boll-weevil tubing head

The boll-weevil hanging method is used for oil wells since the requirements imposed on
the sealing are not as strict as those for gas wells, as the pressures are lower. A polished
hanger nipple is also used here, with notches for installation of plugs by the Wireline
department.
Hanger nipple Spherical cone with packing component

Packing ring Packed pressure bolt

Guide pin

Wireline plug rabbet

Lip
Chamber

Boll weevil

Polished for sesaling the wireline plug

Tubing

Boll-weevil hanging

The short hanger nipple is tube-threaded on both sides: on one hand to establish the
connection between the hanger nipple and the tubing, and on the other hand so that the
boll-weevil hanger assembly can be put into position in the boll-weevil spool through the
BOP by means of auxiliary tubing screwed into the top.

The boll-weevil hanging is a combination of a boll-weevil hanger assembly and a boll-

weevil spool, which is installed on the top most casing head spool. The boll-weevil hanging
consists of a spherical cone fitted with a packing ring. The purpose of the pressure bolts is
to compress the packing component in order to obtain a good seal between the tubing and
the casing head. A plug can be screwed into the hanger nipple to allow for pressure testing
and for temporary protection when the above-ground well completion is exchanged.

Sometimes a Cameron type H two-way check valve (a non-return valve that works in two
directions) is installed so that the well can be temporarily shut down when the above-
ground well completion or adaptor are exchanged for a BOP, or vice versa. This valve has

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two seats and seals both above and below the valve (function of an inside BOP) and is
thus also suitable for pressuring test the BOP.

The valve is loosened and pulled with a special pulling tool, whereby any pressure under
the valve can be equalised, either with or without the use of a lubricator. The tubing stack
is screwed into the bottom most threaded box. Its tensile stress is transferred to the
casing head via a chamber with lip and the cone.

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4. Christmas-tree

4.1. Summary of the Christmas-tree

The Christmas-tree is the part of the above-ground well completion between the tubing
head and the flow pipe. The purpose of the Christmas tree is to provide the option of
closing the gas and/or oil flow off from the formation by means of a manually operated
valve or by means of an automatically operated valve: the Otis valve. Furthermore, the
flow pipe can be opened or closed by means of the flow-arm valve.

Above-ground, gas wells are completed to as great an extent possible with a production
cross forged from one piece (solidblock Xmas tree), which consists of one body or
housing in which the various valves are installed. Older gas wells are still equipped with a
composite production cross (composite Xmas tree). The various cut-off valves are
assembled together in a so-called Y-form block.

In comparison to the composite cross, the forged cross has the following advantages:
Noticeably fewer flange connections, thus less chance of leakage, which above all
provides more safety in case of a blowout or a fire in an adjacent well.
Less high, thus more easily accessible to operating personnel; moreover, a lower
well cage will suffice.

A disadvantage of the forged production cross in comparison to the composite production

cross is apparent when damaged valves are changed. It may happen that the body is
seriously damaged near one of the wing valves (e.g. the flow arm valve) or near the top
valve. In that case, the entire Xmas tree must be exchanged and thus the entire well must
be killed. In case of a composite production cross, the entire Y piece with wing valves and
top valve can be changed, for example, just by closing the two master valves.

For various reasons there are two main valves, the master valve and the Otis (also
referred to as the first and second master valves):
First of all, the gas flow can be shut off by means of the manually operable valve if
the Otis valve is not closing for one reason or another, while this is desired.
Second, statutory safety requirements stipulate that installation components may
only be worked on if two closed valves are installed in series, between the
pressurised part of the installation and the pressure-free part. This implies that if
the flow pipe valve must be repaired, for example, this can take place in safe
conditions if both master valves are closed and the pressure-free part, in which the
flow pipe valve is installed, has an open connection to the atmosphere.

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4.2. The solid block Christmas tree

The solid block Christmas tree is used for most gas wells. These consist of a forged steel
block, which includes the valves.

Top + cap

E-top valve

C-tubing-
casing-
connection valve Flow-arm valve
Otis operated master
valve
Flow line
Sandfilter
bypass
Master valve

Tubing-casing
connection Intermediate flange
Tubing-head spool (type LDO)
Bril flange
Scheme
Kill pumpline

Non return valve L zero point

for wireline depth gauge
Casinghead spool
Alarm
switch

Casinghead
housing

5 VAM casing as return

stack
7 casing
10 3/4 casing
16 casing
20 stovepipe

The solid block Christmas tree

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The Christmas tree consists of the following components:

the manually operable master valve

the Otisoperated master valve
the block in which the valves are installed
a flow arm valve
a top valve
an additional valve on the other side of the flow arm valve
a top connection with cap (access for well service activities).

The Otis valve is similar to the bottom master valve, with the difference that an automatic
operating mechanism is installed instead of a hand wheel. This operating mechanism,
usually called the Otis actuator, is activated when the pressure in the Christmas tree
drops too low. This may be the case, for example, if a pipe ruptures or if the NTS or
flapper valve in the tubing closes.

The Otis actuator also closes the valve if the control air required to operate Otis stops
flowing or if a failure occurs in the installation. There is also the option of closing the Otis
during regular production from the control room by means of an electrical signal. The Otis
valve is of great importance for safety.

The gas supply to the production installation can be closed off by means of the flow arm
valve.
The top valve is a vertical access required for a large number of well service activities,
such as wireline, perforation and stimulation.

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4.3. The components of the composite Xmas tree

Top + cap

E-top valve

Flow-arm
valve
C-tubing-casing
connection valve Otis operated
master valve Flowline
pilot
solenoid
Sand filter
Y-shape 3 bar air
Bypass
block
Orifice
union
Tubing-casing
connection Master valve
Tubing-head spool (type LDO)
Brill flange
scheme
Kill pump line

Non return valve L

Zero point for wireline dept gauge

Casing head
Alarm spool
switch

Casinghead
housing

5 VAM casing as return

stack
7 casing
10 3/4 casing
16 casing
20 stovepipe

The composite Xmas tree

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The composite tree is put together from separate components. This Xmas tree consists of
the following components, from top to bottom:

the manually operable master valve

the Otis valve (secondary valve)
the 3-way piece
the valve for the tubing casing connection
a flow valve
a top valve
a top connection with cap

Various valves are installed on the 3-way piece:

the Otis valve at the bottom
three valves from left to right at the top:
o the valve in the tubing casing connection
o the top valve with the top connection on it
o the flow pipe valve

The tubing casing connection serves to release excessive pressure in the annulus to the
flow pipe via the tubing casing connection valve. The top valve with connection serves to
enable wireline work. The flow line valve can shut off the gas supply to the installation.

A choke is installed in some cases past the flow pipe valve. One can make a well produce
at different speeds by means of various chokes. In most cases, however, one is liable to
find the choke in the installation.

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4.4. The Xmas tree for the production cross for gas lift oil wells

The Xmas tree is built out of the following components:

casing hangers and nipples
flow line
gas lift supply pipe
the usual valves.

bullplug
The flow line is equipped with a
T-piece hand choke, which is used when
the well is started. Remote
Production valve operable valves (ROVs) are
installed in the gas lift pipe as
well as in the flow line. The ROVs
are connected to a number of
Xmastree cap shut-down actions; the latter
depends on the situation (hot
Adapter flange well, H2S well, etc.)

Top valve or Examples of shut-down actions

lubricator valve
Flow wing of are:
Injection valve
On ROV in flow line
o HPSD high pressure
T piece
shutdown
o LPSD - lowpressure
Master valve or shutdown
main valve o HTSD high temperature
Tubing-casing shutdown
Adapter flange connector
Tubinghead spool On ROV in flow line and gas
(boll weevil) Liftgas lift pipe
Casingheadspool o Leak alarm
o H2S alarm
Emergency stop from the
Casing valve measuring station
Casinghead housing
If a corrosion inhibitor pump is
Conductor installed, it will also stop at a
valve shut-down action.
4 1/2", 3 1/2 or 2 7/8
7
10 3/4
24

16

Example of a Xms tree for gas lift oil wells

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 4.5. The Xmas tree setup on clusters

As indicated in the figures in the preceding two chapters, all onshore wells have a cellar.

Top cap
Top valve (open)

Closed and blinded off Flow line (injectionline) The purpose of the cellar is to
keep the most frequently used
Flow-arm valve (open) master and operating valves
Tie-line valve
of the Xmas tree at a workable
No tubing-annulus height and to catch any small
connector pipe Otis-actuated master valve
(main valve) oil or condensate/servo leaks.
In principle, cellars are never
Hand operated master valve made any bigger than strictly
necessary to accommodate
the part of the above-ground
completion, such casing head
Sealed in open position housing, casing head spools,
tubing head spool and annulus
Tpiece connections.

1/2 kerotest valve The annulus valves,

Controlline outlet connection and tapping
facilities are not operated on a
daily basis. One must descend
into the cellar for this, unless
Intermediate deck extension tools are used. The
accumulated rain water is
suctioned from the cellar from
time to time. The depth of the
Intermediate platform
cellar can be approximately
2.5 metres or more,
depending on the number of
casings to be sealed off from
one another and the type of
the well. The immediate
environment is also taken into
consideration by keeping the
tree as low as possible. Some
completions are recessed in a
cellar for the greater part.
cellardeck

Above-ground well structure of an offshore gas well

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The Xmas tree setup on platforms
The space available on offshore production platforms is restricted as a result of which the
freedom and options during design are also reduced. Platforms have no cellar, but a cellar
deck is still referred to. Stairs with an intermediate platform are installed from the cellar
deck to operate the valves.

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5. Gate valves

5.1. Summary of Gate valves

The gas and oil industry makes frequent use of gate valves.

Gate valves are the only valves installed in the Christmas tree. These valves must meet
various requirements. We will discuss two sealing principles for this type of valves at this
point.

The gas the Christmas tree and the valves are in contact with is at high pressure, can
contain H2S and can contain fluid or sand particles. The high speeds of the gas that are
generated when the valve is opened and closed require special sealing provisions to limit
wear from erosion.

5.2. The principle structure of a gate valve

In principle, a gate valve consists of a body with exchangeable, parallel seats, in which the
gate can move.

A packed screw stem with

handwheel Internal thread (left)
pressure bearing is installed in the
bonnet or cap of the valve. The
Pressure bearing
gate can be opened or closed by
Packing
turning the hand wheel of the
Seal stem, since the gate is moved
upward and downward along the
Cap or bonnet
thread of the stem. If the gate is
in the closed position in the
Screw spindle
bottom of the body, one uses the
House or body term 'direct acting valve'. There
are also valves whereby the gate
Gate rather seizes against the cap or
bonnet in closed position. This
type is called 'reverse acting
valves' and they are used in
Christmas trees in combination
Exchangeble seat
with an Otis U (pneumatic and
hydraulic) and UX actuator.
Principle of a direct acting gate valve Clockwise rotation of the hand
wheel closes a direct acting valve.

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The two gate valves we will discuss are both direct-acting valves. They have a nonrising
stem. One cannot see from the outside whether the valve is open or closed. Gate valves
are open/close valves and not control valves. The valve may never be left in the middle
position, thus half open and half closed, for example.

If the hand wheel of an open gate valve (at the top gate position) is turned counter-
clockwise, it will seize up because the left-hand thread of the stem comes to the end of the
thread in the gate (Cameron type F) or in the lift nut (McEvoy model C). If the gate
valve is closed, the hand wheel also seizes against a shut-off valve if turned clockwise any
further. For these valves tightening the hand wheel has no effect on sealing, but it does
close the sealing valve installed for changing the stem packing.

After the valve has been opened or closed, one must turn the hand wheel back at least a
quarter turn to prevent the thread between the stem and the gate as well as the gate itself
from seizing. Such seizing up can be aggravated by temperature variations during
production and production stops and by the ambient temperature. Turning back a quarter
turn also assists with detecting the closed/open position of the valve, namely by first
turning the hand wheel clockwise. If the valve is closed, the hand wheel blocks after a
quarter turn or half a turn, and in open position one can rotate further (direct acting
valves).

5.3. Requirements set for valves

Valves must above all be safe. This leads to a number of technical requirements, such as:

Valves must be bubble tight, even though there is dirt in the gas or the valve is
slightly damaged. It often happens that valves start leaking anyway after some
time, so that pressure is built up past the closed valve. The speed at which the
pressure builds up depends on the volume of the space past the valve and the
magnitude of the leak.
The valve must be operable under all conditions, even if the valve separates a large
pressure difference, i.e. operable by one person (opening/closing).
The number of turns required to open and close the valve must be limited.
If the valve is open, passage must be straight, thereby preventing or limiting
turbulence (erosion).
The valve must be resistant to corrosive and/or erosive components in the oil or
gas as well as to weather and wind.
The valve must be resistant to very high well pressures.

The following requirements are set for maintenance work on a valve:

valves must be of such structure that the packings and the bearings of the gate
spindle can be inspected and/or replaced during production without removing the
valve or releasing the pressure on it
valves must make it possible to replace the gate or the seats at the location;
valves must require little maintenance.

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5.4. The method of sealing gate valves

Gate valves can be sealed in various ways. Different methods are used for the gate valves
in use in the gas and oil industry. We will succinctly discuss the two most important
methods:
Metaltometal seal method
Sealingcompound method.

Metaltometal seal method

If a valve is in the closed position, the valve will be under full pressure, while there will be
lower pressure past the valve. This pressure difference results in a force.

A packed screw stem with

pressure bearing is installed in
handwheel Internal thread (left) the bonnet or cap of the valve.
The gate can be opened or
Pressure bearing closed by turning the hand
Packing
wheel of the stem, since the
gate is moved upward and
Seal downward along the thread of
Cap or bonnet the stem. If the gate is in the
closed position in the bottom of
Screw spindle the body, one uses the term
'direct acting valve'. There
House or body
are also valves whereby the
gate rather seizes against the
Gate
cap or bonnet in closed position.
This type is called 'reverse
acting valves' and they are
used in Christmas trees in
Exchangeble seat combination with an Otis U
(pneumatic and hydraulic) and
UX actuator.
Clockwise rotation of the hand
wheel closes a direct acting
Principle of a direct acting gate valve valve.

5.5. Sealing compound method

The force due to the pressure difference on the valve is often insufficient to guarantee a
100% seal.

Moreover, bigger leaks can be caused by irregularities or scratches.

For these reasons, an additional sealing compound is applied automatically between the
gate and the seat to ensure complete sealing. The surfaces of the gate and the seat are
then finished normally smooth and parallel.

This sealing method is used in the McEvoy valves.

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 Screwcap Hand wheel
Seal valve and slanted Grease nippel
seat for exchanging
packing and bearing Pressure bearing

Spindle packing

Bonnet

Nipple with venting plug

Lefthand threaded screw spindle

Piston

Reservoir for sealing compound

lift nut to move

the gate along
the spindle

Slide block

Exchangeble seats
Space for water-repellent grease

Mc-Evoy gate valve - model C (closed position)

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5.6. The McEvoy gate valve, model C
All McEvoy solid block Christmas trees are equipped with this type.

Screwcap

Seal valve and slanted Bonnet

Grease nippel
seat for exchanging
packing and bearing Pressure bearing

Spindle packing

Bonnet

Nipple with venting plug

Lefthand threaded screw spindle

Piston

Reservoir for sealing compound

lift nut to move

the gate along
the spindle

Slide block

Exchangeble seats

Space for water-repellent grease

Mc-Evoy gate valve - model C (closed position)

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The gate of the McEvoy gate valve consists of two parallel halves kept apart against the
seats by pressure springs. Because the gate is parallel, it cannot seize between the seat
rings, and additional tightening of the hand wheel has no effect on the seal. The valves in
gas flows can be subject to more serious erosion at the time the gate practically closes the
passage. The two so-called sealing surfaces must be very smoothly polished to guarantee
complete sealing.

The eventual seal between the gate and the seats in the McEvoy valve is established by a
special sealing compound.
This compound is stored in two reservoirs on either side of the gate. The reservoirs can be
topped up via external grease nipples, which is very important for correct performance of
the valve. The advantage of this type of valve is that if any leakage is detected, it can
easily be remedied in a short time by injecting a sealing compound.

The space underneath the gate can be filled up with water-repellent grease to prevent
accumulation of fluids, hydrates and dirt.

5.7. The Cameron gate valve, type F

The Cameron gate valve, type F (see figure). A great deal of research has been done to
limit wear of the gate and the seat and to find a good solution for such wear. Gas flows
through a very narrow space at high speeds especially when a valve is just being opened
and nearly closed. The erosion that occurs at that time is extensive and the wear on the
gate and the seat as well as leakage appearing at a later stage will be the result.
The Cameron gate valve is fitted with a seat that can rotate (rotating seat). The intention
of this is that a new piece of the seat is exposed to wear by the gas flow each time. This
way, the wear of the seat is distributed evenly across the entire circumference.

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 Hand wheel connection piece Hand wheel

Shear pin Pressure bearings

Pressure piece Screw spindle with left hand thread in gate

Screw cap
Grease nipple, also pressure
release with non-terun valve Packingcap

Bonnet flange

Seal valve and slanted seat for sealing

when the packing set is exchanged

Center pin

Gate

Seat

Teeth aong the circumference Palm mechanism

Cameron gate valve type F (closed position)

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The valves are mostly not fitted with a rotary seat and a catch mechanism. Problems
caused by teeth breaking off were more serious than the advantages.
The valve gate is not shared and moves back and forth between two seats through a
threaded stem. The seal is formed by a metal to metal seal. The gate and the seat require
a very accurate and smooth finish for this reason. In order to protect the gate, the stem
and other internal parts from overload, the force applied to the hand wheel is transferred
to the stem via a shear pin. This shear pin is not part of the McEvoy gate valve, model C.

The forces on the stem during operation are absorbed by two pressure bearings. One
packing set, enclosed by a screwed pressure piece, ensures that no leakage can occur
along the stem. Since the packing pressure piece is attached by means of thread, the
pressure bearing at the Cameron valve can be exchanged under pressure without other
precautions being taken. If the packing set must be changed during production, the space
for this above the packing can be closed off from the pipe pressure, just as is the case for
the McEvoy valve.

A slanted disc (front) is installed on the stem, which moves up after the valve is closed by
turning it further clockwise (due to the left-had thread in the gate) and will seal against
the slanted seat in the bonnet flange. The pressure that prevails above the slanted seat
can be released via the lubrication nipple with the non-return valve. To do so the ball is
pushed from its seat by means of a special tool, whereby the pressure can be released.
The screw cap can be safely turned loose and the packing set inspected or replaced only
after no more gas is escaping.

Tightening the hand wheel has no effect on the seal, just as is the case for the McEvoy
valve. Maintenance of the valve is simple thanks to its structure. The seats and the gate
can easily be replaced. Depending on the use, the valve must be lubricated from time to
time. One disadvantage of the Cameron valve type F is that, if it turns out during wireline
work that the valve leaks, it must first be repaired, while the McEvoy valve, model C, can
usually be sealed again by refilling up the sealing compound reservoir.

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