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FMC SURFACE WELLHEAD
T
About his Catalog This catalog is both a brochure about
tions. There are a number of key
and services, global reach and a
our company and a catalog of our
drivers that factor into those deci-
robust HSE-driven commitment to
fine products, systems and services.
sions, not the least of which is the
safety with a safety record that no
reputation of the company whose
competitor can match.
Along with the knowledgeable
We ask you to take a moment
brand is on the product.
advice of your FMC Surface
to learn more about our company,
What FMC Surface Wellhead
Wellhead representative, this publication is designed to help you make
brings to the decision-making
its unique strengths and capabilities
informed decisions in specifying the
process is a unique combination of
and why we should be your surface
best, most cost-effective solutions
experience, performance, techno-
wellhead vendor of choice.
for your surface wellhead applica-
logical leadership, quality products
TA B L E O F C O N T E N T S
TA B L E O F C O N T E N T S ◆
FMC Surface Wellhead at a Glance
1
◆
FMC Surface Wellhead: an Overview
2
The FMC Energy Systems Story. Technology. Products & Systems. Wellhead Economics. Our People & Our Commitment to Safety ◆
FMC Surface Wellhead Drilling Solutions
12
◆
FMC Surface Wellhead Drilling Products
20
◆
FMC Surface Wellhead Completion Solutions
34
◆
FMC Surface Wellhead Completion Products
42
◆
FMC Surface Wellhead Systems Solutions
54
◆
FMC Surface Wellhead Actuators, Valves, Seals 62
◆
FMC Surface Wellhead Technology Capabilities 86
◆
FMC Surface Wellhead Aftermarket Service,Tools 92
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OVERVIEW
Who
We A re
F r o m D a y O n e : L i s t e n i n g t o t h e C u s t o m e r. In August 1927, brothers Arthur and Kirby Pennick of Houston founded Oil Center Tool (O-C-T) to produce pump liners and rods for the oilfields of East Texas. In 1930, O-C-T introduced a new type of casing head and tubing head that was an immediate success. ➤ O-C-T soon followed these innovations with another first. At the time, completion wellheads (Christmas trees) were assembled and tested on-site – an expensive, time-consuming and dangerous practice. O-C-T had a better idea, along with better completion wellhead components. The company introduced the first factory-assembled and tested Christmas tree, an innovation hailed as a landmark in efficiency, safety and cost-effectiveness. ➤ After only a few years of operation, O-C-T was on its way to setting the standard for the design, manufacture and service of the surface wellhead. The Our Company at a Glance
company that would become part of FMC Energy Systems – a quarter of a century later – introduced one innovation after another as it committed its resources to designing and manufacturing superior wellhead systems for a growing roster of customers. It’s been that way ever since.
TECHNOLOGY LEADER
FMC Energy Systems and its predecessor, O-C-T, have a long history of technological innovations – from the 5K wellhead in the 1930s to the first multiple-completion systems of the 1940s to the first Unihead™ thru-bore system – and in subsequent decades, the introduction of multiple-completion systems, automatic casing hangers, Unitree™, industrystandard C22/29 casing heads, Speed Loc™ clamps, subsea technology and the first
[
S A F E T Y F I R S T.
When we partner with you to work out the specifics of your
wellhead requirements, the first topic on the agenda is always “Safety.” Safe products and practices impact every aspect of the successful drilling and completion of a well. With this in mind, FMC Surface Wellhead is consistently the industry leader in safety.
]
TLP/SPAR systems.
2
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Page 1
OVERVIEW
Who
We A re
F r o m D a y O n e : L i s t e n i n g t o t h e C u s t o m e r. In August 1927, brothers Arthur and Kirby Pennick of Houston founded Oil Center Tool (O-C-T) to produce pump liners and rods for the oilfields of East Texas. In 1930, O-C-T introduced a new type of casing head and tubing head that was an immediate success. ➤ O-C-T soon followed these innovations with another first. At the time, completion wellheads (Christmas trees) were assembled and tested on-site – an expensive, time-consuming and dangerous practice. O-C-T had a better idea, along with better completion wellhead components. The company introduced the first factory-assembled and tested Christmas tree, an innovation hailed as a landmark in efficiency, safety and cost-effectiveness. ➤ After only a few years of operation, O-C-T was on its way to setting the standard for the design, manufacture and service of the surface wellhead. The Our Company at a Glance
company that would become part of FMC Energy Systems – a quarter of a century later – introduced one innovation after another as it committed its resources to designing and manufacturing superior wellhead systems for a growing roster of customers. It’s been that way ever since.
TECHNOLOGY LEADER
FMC Energy Systems and its predecessor, O-C-T, have a long history of technological innovations – from the 5K wellhead in the 1930s to the first multiple-completion systems of the 1940s to the first Unihead™ thru-bore system – and in subsequent decades, the introduction of multiple-completion systems, automatic casing hangers, Unitree™, industrystandard C22/29 casing heads, Speed Loc™ clamps, subsea technology and the first
[
S A F E T Y F I R S T.
When we partner with you to work out the specifics of your
wellhead requirements, the first topic on the agenda is always “Safety.” Safe products and practices impact every aspect of the successful drilling and completion of a well. With this in mind, FMC Surface Wellhead is consistently the industry leader in safety.
]
TLP/SPAR systems.
2
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The more You know about us, the more you’ll specify FMC Surface Wellhead products.
SAFETY
GL O B A L R E A C H
FIRST
Manufacturing, engineering and
Our top-down, bottom-up com-
testing; sales, service and ongo-
mitment to safety in products and
ing support: where there’s oil and
practices results in the industry’s
gas exploration and production,
lowest incident rate. Safety is
FMC Surface Wellhead is there.
fundamental to the FMC Energy Systems culture.
Covering the worldwide oil patch with over 100 locations around the world
O
V
E
R
75 Y E A R S
PIONEER AND INNOVATOR. For more
TECHNOLOGY. FMC Surface Wellhead’s
PRODUCTS. From standard flanged
than 75 years, we’ve supported your industry’s quest for improved wellhead performance and safety. Today FMC Surface Wellhead is one in a family of technologically related businesses providing innovative solutions for producing and processing oil and gas.
substantial investment in R &D and Applied Engineering – which includes advanced, full-scale testing laboratories – assures continual innovation as well as continual improvements and enhancements in our products and services across the board.
wellheads to custom-engineered criticalservice systems, FMC Surface Wellhead offers a broad spectrum of products and systems to fit your budget and performance parameters, wherever the well, whatever the application.
THE BOTTOM LINE. A wellhead represents only 3-5% of the cost of a well, but what a vital investment! Choosing precisely the right solution for your well can reduce both drilling and completion costs. FMC Surface Wellhead can help you to optimize your bottom line.
OUR PEOPLE. You ask, we listen. From engineering to sales to service, at the end of the day, this business is about one-to-one relationships: the knowledgeable, experienced, dedicated individuals of FMC Surface Wellhead sitting down with you to listen and to work out solutions for your needs.
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OVERVIEW
T
Top echnology
FMC Energy Systems. FMC Corporation acquired O-C-T in 1957 and
FMC
committed the assets to enhance manufacturing and
Surface in
Wellhead
Innovations
Te c h n o l o g y
service capabilities, grow the business into the offshore sector and expand internationally. FMC, itself an innovator in agribusiness and food processing technologies, traces its history back more than 100 years. In 1973, the former O-C-T was renamed FMC’s Wellhead Equipment Division. In 2002, FMC became two separate and now unrelated companies: FMC Corporation (agricultural products and chemicals and industrial chemicals), and our parent company, FMC Technologies (NYSE: M E E T T H E F A M I LY
FTI). FMC Technologies has over $2.0 billion in sales,
From our roots in 1927, our company’s history of service to your industry is a record of listening to the needs of our customers and developing and upgrading the technology to fulfill those needs – on the fastest possible track. We understand budget and risk parameters. We understand performance requirements. And we know time is money. Your money.
more than 8,500 employees worldwide and 32 manu-
Energy Production Systems
facturing plants in 15 countries. The company consists
FMC Surface Wellhead’s resources
of FMC Energy Systems, FMC Airport Systems and
consist of diverse teams of engineers
FMC Food Tech.
and fire-resistant applications. We support them with state-of-the-
Our ISO-9000- and API-certified, highly automated manufacturing
and technicians that include
art materials-analysis laboratories
facilities feature robotics technology
FMC Kongsberg Subsea
FMC Energy Systems accounts for more than
specialists in valve design, wellhead
equipped to provide full-scale product
and world-linked CAD technology
FMC Surface Wellhead
$1.3 billion of our parent company’s annual revenues,
equipment design, sealing technology,
testing that replicates actual environ-
as well as the environmental test labs
with FMC Surface Wellhead being a significant
metallurgy, finite element analysis
mental and operating conditions.
and engineering / testing facilities.
FMC SOFEC Floating Systems MODEC International LLC
contributor to this amount.
CDS Engineering
Consisting of nine distinct but integrated and
Energy Processing Systems
synergistic operations, FMC Energy Systems is a leader
FMC Fluid Control
in the design, manufacture and supply of oil and
FMC Loading System
gas exploration, production, measurement, control and
FMC Measurement Solutions
transportation technologies.
FMC Blending & Transfer
3
4
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OVERVIEW
T
Top echnology
FMC Energy Systems. FMC Corporation acquired O-C-T in 1957 and
FMC
committed the assets to enhance manufacturing and
Surface in
Wellhead
Innovations
Te c h n o l o g y
service capabilities, grow the business into the offshore sector and expand internationally. FMC, itself an innovator in agribusiness and food processing technologies, traces its history back more than 100 years. In 1973, the former O-C-T was renamed FMC’s Wellhead Equipment Division. In 2002, FMC became two separate and now unrelated companies: FMC Corporation (agricultural products and chemicals and industrial chemicals), and our parent company, FMC Technologies (NYSE: M E E T T H E F A M I LY
FTI). FMC Technologies has over $2.0 billion in sales,
From our roots in 1927, our company’s history of service to your industry is a record of listening to the needs of our customers and developing and upgrading the technology to fulfill those needs – on the fastest possible track. We understand budget and risk parameters. We understand performance requirements. And we know time is money. Your money.
more than 8,500 employees worldwide and 32 manu-
Energy Production Systems
facturing plants in 15 countries. The company consists
FMC Surface Wellhead’s resources
of FMC Energy Systems, FMC Airport Systems and
consist of diverse teams of engineers
FMC Food Tech.
and fire-resistant applications. We support them with state-of-the-
Our ISO-9000- and API-certified, highly automated manufacturing
and technicians that include
art materials-analysis laboratories
facilities feature robotics technology
FMC Kongsberg Subsea
FMC Energy Systems accounts for more than
specialists in valve design, wellhead
equipped to provide full-scale product
and world-linked CAD technology
FMC Surface Wellhead
$1.3 billion of our parent company’s annual revenues,
equipment design, sealing technology,
testing that replicates actual environ-
as well as the environmental test labs
with FMC Surface Wellhead being a significant
metallurgy, finite element analysis
mental and operating conditions.
and engineering / testing facilities.
FMC SOFEC Floating Systems MODEC International LLC
contributor to this amount.
CDS Engineering
Consisting of nine distinct but integrated and
Energy Processing Systems
synergistic operations, FMC Energy Systems is a leader
FMC Fluid Control
in the design, manufacture and supply of oil and
FMC Loading System
gas exploration, production, measurement, control and
FMC Measurement Solutions
transportation technologies.
FMC Blending & Transfer
3
4
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Overview
O ff s h o re a n d S u r f a c e C o m p l e t i o n
Standard API flanged wellheads
Floating Storage and Offloading (FSO) vessels Offshore loading systems
Large-bore Unihead® wellhead systems
Tension-leg platforms External turret mooring systems
SOFEC marine import/ export terminals
Floating Production, Storage and Offloading (FPSO) vessels
Smith metering and control systems ®
®
Chiksan and Weco flowline equipment Coiled-tubing completion equipment
Turnkey blending facilities Smith metering equipment AccuLoad® load controllers
Injection and production manifolds Piston and plunger pumps Platform wellhead and tree systems Kongsberg metering and control systems
SOFEC service buoys
Production manifolds Light well subsea interventions Smith metering and control systems
Internal turret mooring systems
Chiksan® marine loading arms Access gangways Fire suppression towers Smith metering and control systems Truck loading arms Smith metering equipment AccuLoad® load controllers Rail car loading arms Smith metering equipment AccuLoad® load controllers
UWD-15 subsea drilling systems Horizontal subsea trees Light well subsea interventions
UWD-15 subsea drilling systems
Subsea processing
Subsea manifolds Smartwell control systems Host ® guidelineless systems
Standard subsea manifolds Standard subsea trees
FMC Surface Wellhead
ROVCON tie-in systems
Guidelineless subsea trees
one of nine operating units of FMC Energy Systems. Together, our businesses constitute a global leader in the design, manufacture, service and supply
of oil exploration, production, measurement and transportation technologies. This illustration portrays FMC Surface Wellhead and the other FMC Energy Systems businesses in their elements on land, at sea, offshore and the ocean floor.
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CRITICAL-SERVICE A P P L I C AT I O N S
Wellhead performance is about the performance of your valves and seals. Innovations in valve design and in elastomer and metal-tometal seals technology, long experience in engineering and servicing wellheads for Arctic service and other extreme environments, and state-of-the-art expertise in materials have made FMC Surface Wellhead a leader in criticalservice applications, including: Extreme Sour Service Extreme Corrosive Service o ➤ (-75 F) Arctic Service ➤ Fire-Resistant Technology ➤ High Flow-Erosive Service ➤ ➤
5
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➤ Elastomer SEAL TECHNOLOGY
Higher pressures, well-treatment chemicals, hotter production and longer frac times accelerate the wear and tear on seals, reducing useful life. And if one seal in a wellhead fails, it can blow the budget with lost production and workover time.
Seals Conventional O-ring elastomer seals no longer meet the industry’s stringent design and safety criteria. FMC Surface Wellhead has developed seals that compensate for thermal expansion and contraction, and the larger API casing and tubing tolerances that create increasingly difficult sealing conditions. At the same time, we’ve developed proprietary new elastomers suited to the design parameters of the new FMC Surface Wellhead seals, providing the best combination of mechanical properties and chemical resistance. We design and manufacture our elastomer seals.
V A LV E T E C H N O L O G Y S E T S I N D U S T R Y S TA N D A R D S
Anywhere in the world, in applications ranging from mature low-pressure oilfields of West Texas to critical-service environments from the North Slope to the China Sea, FMC Surface Wellhead is the first name in gate valve technology. We are continually adding value to our superb family of gate valves by listening to your needs, applying engineering improvements to our proven products and making them more cost-effective.
FMC Surface Wellhead offers all Model 100 Series Valves in independent loosevalve configurations for wellhead, tree and manifold applications. Model 100 series valves can also be supplied in composite block configurations for tree and boarding valve applications to suit customer’s special applications and requirements.
6
➤ Metal-to-Metal
Seals Our oilfield customers look to metal seals as cost-effective technology for extending service life and improving production efficiency. In general, metal seals last longer and provide more reliable service, especially in critical applications. FMC Surface Wellhead’s patented “bump” metal seal is regarded as the technological breakthrough in metal seals for wellheads. We manufacture both self-energized, straight-bore, metal seals and externally energized seals.
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LABORATORIES
Temperature chamber: -75oF to 500oF ➤ Pressure testing: 30ksi gas ➤ Computer-automated testing ➤ 2 million lbs. hydraulic ram ➤ Bending load fixture: 8 million ft.-lbs. ➤ Fire test facilities ➤ Optical microscopy and metallography ➤
TEST
CAPABILITIES
Autoclave corrosion testing ➤ Mechanical load testing ➤ Pressure and thermal cycle testing ➤ Fire-resistance testing ➤ Arctic service testing ➤ Hot oil testing ➤ Fatigue testing ➤ NDE-submersion UT, PT and mag particle testing ➤ Hardness testing ➤ Strain gauge testing ➤ Tensile testing ➤ Rheometric testing ➤
C22-EG Casing Spool
FMC KONGSBERG SUBSEA:
SHARED TECHNOLOGICAL ADVANCES
FMC Surface Wellhead was born on land and migrated to the sea. As FMC Energy Systems grew and expanded, the organization was restructured to concentrate like technologies and services into nine highly specialized operating units, including FMC Surface Wellhead. Our sister enterprise, FMC Kongsberg Subsea, which is number one in its global market, grew partly out of the original FMC/OCT wellhead technological group. Today, FMC Surface Wellhead and other FMC Energy Systems operations and their customers benefit from the technology advances developed by FMC’s Energy Systems subsea unit, developing drilling and completion systems for seabed wells, the most hostile of environments for oil and gas production. A notable example, our C22-EG Casing Spool. Its bowl protector retaining subsea technology doesn’t need costly lockdown screws, increasing safety by eliminating the need to work under BOP and potential leak path.
7
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OVERVIEW
T
Standard o Custom The FMC Surface Wellhead Product Line: Standard Flanged Wellheads to Custom-Engineered Systems
Our company is proud to be recognized for its history of technological innovation and its reputation for custom-engineered drilling and completion wellhead systems. But that’s only a narrow slice of what FMC Surface Wellhead offers: In 75 years of listening to your industry, our company has developed a broad spectrum of wellhead drilling and completion components, systems and services. Our C-22 casing head components, for example, introduced in 1962, quickly became the industry standard for this class of product and remain in high regard among company men, drilling engineers and crews, even as we continue to improve and enhance this outstanding line.
For our customers, this broad range of solutions translates into the convenience of relying on a single source – FMC Surface Wellhead – to supply you with exactly what you need for your application, no matter what it is, where it is, how routine or how challenging. For many wells, a standard flanged API wellhead rated at 2,000 psi is the best choice for the budget and risk parameters. For deep critical-service
wells, reliability is the driver: a customengineered project approach may be the best solution. As location, depth, pressures, number of completions per well and other factors complicate the scope, hazards and degree of difficulty of a project, FMC Surface Wellhead is there with a solution that optimizes performance and minimizes your total well cost.
Range of Wellhead Systems Location
Wellhead System
Operator Application
Operator Benefit
Oklahoma
Basic Flanged
Low-pressure gas
Economical
Barinas
Conventional Flanged
High-pressure oil
Standardization and Reliability
Ohanet
Unihead ® Drill-thru
Intermediate-pressure oil
Rig Savings/Intermediate pressure rate
Gulf of Mexico
TLP/SPAR
High-pressure, high-fatigue loading
High reliability in demanding environment
Java Sea
SXS Conductor sharing
Increase production on existing platform
Additional wells per slot
North Sea
Fully Featured
Critical Service
Safety (HSE) and flexibility
8
Working Pressure
PSL Level
3,000 psi
1
10,000 psi
2
6,650 psi
2
10,000 psi
2/3
5,000 psi
2/3
5,000 psi
3
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Oklahoma, U.S. Basic Flanged Wellhead System
Gulf of Mexico, U.S. TLP/SPAR Wellhead System
Page 13
Barinas, Venezuela Conventional Flanged Wellhead System
Java Sea, Indonesia SxS (Side-by-Side) Wellhead System
9
Ohanet, Algeria Unihead® Drillthru Wellhead System
North Sea, Norway Fully Featured Critical-Application Wellhead System
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Safety
First
L o w e s t I n c i d e n t R a t e : S a f e t y I s F u n d a m e n t a l t o F M C ’s E n e r g y S y s t e m s C u l t u re Nothing wastes your investment more than rig downtime from failures in equipment and safety practices. We are proud that our safety record outperforms the industry. The stats back this statement: FMC Energy Systems’ Houston facility, for example, logged 7.4 million man-hours without a lost-time incident. FMC Technologies accepts the responsibility to protect the environment and the health and safety of our employees, their families and the public. Health, safety and environment (HSE) performance is a core value and will be managed as an integral part of our business to benefit employees, neighbors and shareholders. All FMC Energy Systems employees are responsible for assuring that we achieve continuous and measurable improvement. With safety as a top-down, bottom-up responsibility – and with results tied to management and employee performance appraisals – our formal HSE safety program identifies and rewards behaviors that improve safety practices. FMC Surface Wellhead conducts ongoing safety training programs with daily, weekly and monthly service safety meetings. We also require formal job-safety analyses (JSAs) for all service jobs. The JSA gives our service technicians a convenient procedure for reviewing the job with the rig crew, heightens the awareness of safety risks, and focuses on using the right tools for the job.
Bottom
L ine
Equipment Costs Do Matter FMC Surface Wellhead understands that the cost of your wellhead system is part of your purchasing criteria. We also understand that the best way to reduce your cost is to use the right equipment for your application. The only thing more expensive than a feature you don’t need is a system that does not meet your requirements. For more than seven decades, our company has demonstrated the ability to supply worldwide to the oil industry with wellhead systems that have matched the applications requirements. We know about wellhead equipment, and we know about delivering it around the world. Those make us feel comfortable offering you to reduce your cost by working together in the specification of your requirements. Thank you for taking time to learn more about our company. For additional information, go to www.fmcwellhead.com or contact your FMC Surface Wellhead representative (back cover).
10
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Our
People
The FMC Surface Wellhead culture is built upon performance; safety; customer care; and productive, long-term relationships. The FMC Energy Systems people you know and work with are part of a larger business entity which employs more than 8,500 worldwide. All of them speak the language of oil and gas exploration, development and production – and they speak it in English, Spanish, Arabic, Chinese, Norwegian, Portuguese, French and several other languages. While we’re a large, dynamic and global operation, our relationship with you, our customer, is always local, one-to-one, face-to-face.
11
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DRILLING SOLUTIONS
T
Basic o Advanced
[
The nature of your business has you planning an exploratory well in the Ukraine on one assignment, a batch drilling program in Canada the next, or a deep well in Venezuela the next, and so on, around the globe, exploring and producing oil and gas in a huge variety of locations, weather and well conditions on land and offshore. That’s what you do.
From to
standard
advanced
flanged
wellheads
for
onshore offshore
wellheads applications
This section of our catalog
lights the breadth of tech-
cal challenges, well condi-
presents examples of FMC
nology available from FMC
tions and set of risk factors
Surface Wellhead’s systems
Surface Wellhead.
are quite the same. All the
technology developed to
As we help you specify
support you in whatever
your wellhead equipment,
a surface wellhead vendor
budget, technical and logis-
we’ll be striving for a
who has decades of
tic challenges you may
balance of well economics,
experience in a wide variety
encounter on your next
performance demands and
of drilling situations through-
project. This section high-
associated risks. We realize
out the globe.
that no two budgets, logisti-
12
more reasons to trust in
]
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Drilling Solutions
{
“FMC Energy Systems serves operators worldwide, onshore and
}
offshore. When they recommend wellhead technology, we know they’re looking at experience in environments similar
to what we operate in and applications similar to ours, and offer us the best solution for the project.” MAJOR INDEPENDENT OIL COMPANY
13
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The examples below illustrate a progression of surface wellhead solutions from basic to advanced. The right solution is determined by a balance of rig economics
Rig Savings
and performance/risk factors.
Split Unihead® with Internal Latch
UH-WB Split Unihead®
Single Unihead® with Speedloc®
Standard Flanged
Equipment Cost
R a n g e o f We l l h e a d S y s t e m s S t a n d a rd F l a n g e d ◆ ◆ ◆ ◆ ◆ ◆ ◆
Standard API flanged connections Separate stage for each drilling phase L-packing retention of bowl protectors Automatic slip hangers (depending on application) Elastomer seals Designed to operate up to 20,000 psi wp Uses standard running and installation tools
Benefits ◆ Low CAPEX ◆ Familiarity with standard equipment ◆ Simplicity of installation Considerations ◆ Rig Time ◆ Working under Suspended BOPs
14
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UH-WB Split Unihead® ◆ ◆ ◆ ◆ ◆ ◆ ◆ ◆
Has basic, cost-efficient and time-saving drill-thru design. Separate spools made up as a single unit permit drilling two or more phases without removing BOPs. Has fluted mandrel casing hangers with ACME running threads. J-slot packoffs are held in place with standard lockdown screws. Utilizes lockdown screws for retention and energizing of seals. Has elastomer seals. Is designed to operate up to 10,000 psi wp. Provides option to split drill-thru head to run emergency casing hanger.
Benefits ◆ Offers reduced installation time, lowers costs overall. ◆ Eliminates working under BOP stack, increasing safety. Considerations ◆ Has higher initial CAPEX vs. conventional. ◆ Has through-wall penetrations. ◆ Requires contingency equipment, special tooling.
Split Unihead® with Speedloc® Connections ◆ ◆ ◆ ◆ ◆ ◆ ◆
Split system made up as a single unit permits drilling two or more phases without removing BOPs. Has fluted mandrel casing hangers with ACME running threads. Simple packoffs with metal or elastomer seals are held in place with internal latch. Has FMC Speedloc ® II clamps for drilling risers and connections. Utilizes internal latches or lockdown screws for retention of seals. Offers elastomer and metal-to-metal seal options. Provides option to split drill-thru head to run emergency casing hanger.
Benefits ◆ Offers reduced installation time, lowers costs overall. ◆ Eliminates working under BOP stack, increasing safety. ◆ Minimization of through-wall penetrations reduces operating risk. Considerations ◆ Support service is recommended. ◆ Requires contingency equipment, special tooling.
Single-Piece Unihead® with Internal Latch ◆ ◆ ◆ ◆ ◆
Single-piece Unihead ® permits drilling 18 3/4˝ or 13 5/8˝ two or more phases up to 15K without removing BOPs. Has fluted mandrel casing hangers with ACME running threads. UWD 15 packoffs in metal or elastomer are locked with single-trip hydraulic tool. Has Speedloc® I clamps for drilling risers and fire-resistant connections. Offers high reliability for critical services.
Benefits ◆ Offers reduced installation time, lowers costs overall. ◆ Eliminates working under BOP stack, increasing safety. ◆ Minimum through-wall penetrations and fire-resistant connections reduce safety risks. Considerations ◆ Has higher initial CAPEX. ◆ Contingency equipment, special tooling. ◆ Support service is recommended. 15
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DRILLING SOLUTIONS
[
World
F M C S u r f a c e W e l l h e a d ’s S D - 1 M u d l i n e S u s p e n s i o n S y s t e m i s a n i n n o v a t i v e s o l u t i o n f o r c o n d u c t i n g d r i l l i n g , temporary abandonment and production tie-back operations from a jack-up or other bottom-supported rig. The SD-1 uses a stackdown configuration, with each successive landing sub/casing hanger connection located below the previous one. The standard system is rated to 10,000 psi and is H2S compatible. Higher-strength versions using alternate materials are available.
[
Exploring the
Metal-to-metal seal
S TA C K - D O W N C O N F I G U R AT I O N
M E TA L - T O - M E TA L S E A L I N G
Provides wide-open access to the tie-back profile in each hanger, eliminating trash traps and enhancing the reliability of production tie-back operations.
During drilling, all landing sub and casing hanger connections are secured by metal-tometal seals. For completion tie-backs, two metal-to-metal seals are simultaneously energized, one at the top of the hanger and another at the nose of the tie-back sub.
Drilling
Drilling
P ro d u c t i o n
Landing subs
SD-1 Mudline Suspension System Tie-back subs Casing hangers
Butt-weld sub Expanding spring hanger
16
Production
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O ff s h o re Designed to Save Time, requires only one major Nipple-Up of the BOP The OBS surface equipment used with SD-1 mudline system has been designed to save time in assembly and disassembly of this unique drilling tool. The major time savings occur when the well is being abandoned. Access to the hanger and packoff/support bushing can be achieved by nippling down the connection at the casing head and lifting the OBS system as a single unit.
Op e r a t i o n s
The OBS surface wellhead has three functions: ➤ To suspend casing risers at the rig ➤ To provide for annulus packoff seals between casing risers ➤ To support the BOP stack When the OBS system is being installed, all of the wellhead spools can be installed as a single unit with the BOP stack on top after installation of the casing head and lowermost packoff/ support bushing. All subsequent casing
CM-1 The CM-1 is a subsea tree utilized to complete subsea wells on mudline suspension systems for shallow waters to 400 feet. ➤ Allows fast-track completions resulting in early production. ➤ Proven, cost effective solution for shallowwater marginal field development. ➤ Allows to tie back to most mudline suspension designs.
17
hangers and multifunction packoff/support bushings can be installed without nippling down the BOP stack or inserting additional casing spools. In the system shown, additional time savings are achieved through the use of Speedloc II connections on the spools. These connections allow easy and quick access to install hangers and packoff/ support bushings. OBS surface equipment is furnished with clamp connections for 21 1/4˝ 2K, 13 5/8˝ 5K and 13 5/8˝ 10K.
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DRILLING SOLUTIONS
Time Time-Saving
S avings
Solutions
Since our days as O-C-T, we’ve led the industry in solutions that save rig time and enhance the safety of your operation. Both those aspects were taken into account when we developed our Diverter Attachment wellhead product offering. One of the inherent dangers of the industry is working under the Diverter/BOP stack when it is being installed or removed. The features we have incorporated in our Diverter Attachment Assemblies greatly minimize the amount of time one is required to spend on the wellhead deck during these operations. Time savings were also a strong consideration taken into account during the development of our Diverter Attachment assemblies. Depending on which design best fits your application, we have incorporated such features as no requirement to wait on cement to set, elimination of “hot work,” ability to land multiple casing strings without nippling down and the speed associated with the installation and removal of the Slip Loc and Speedloc ® quick connections. Depending on which design is selected, the operator could achieve between 6 and 36 hours of rig time-savings.
S l i p L o c B o t t o m w i t h 2 - S t e p We l l h e a d f o r A t t a c h i n g t o t h e D i v e r t e r A s s e m b l y : Description The diverter wellhead assembly attaches to the conductor pipe by the use of the time-saving Slip Loc connection. The wellhead is provided with two load shoulders that allow the operator to land and pack off both conductor and surface casing without ever needing to nipple down. F e a t u re s a n d B e n e f i t s ◆ The wellhead bottom is equipped with a Slip Loc connection and the top with a Speedloc® connection. Both these connections save considerable rig time during installation. ◆ Seals the well bore while drilling out for conductor and surface casing. ◆ If used in conjunction with a mechanical casing cutter, this design eliminates the need for welding; thus there are no longer the dangers associated with “hot work.” Further, adjacent wells do not have to be shut in during installation. ◆ The conductor casing string is landed, packed off and tested prior to cementing. If it is desired that returns be taken across the shale shaker, a flow loop can be installed during the cementing operation. ◆ The surface casing is landed on the upper load shoulder with a fluted hanger for flow by. Once cementing operations are complete, the pack off is run, locked in place and tested prior to nippling down. ◆ The diverter riser assembly is removed and subsequent wellheads installed with the use of the Speedloc® connection, which is designed to save valuable rig time. ◆ Available in Slip Loc or butt-weld prep for 30˝, 26˝ & 24˝ drive pipe.
18
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Slip Loc Bottom with contained landing ring with Flanged Top Diverter Adapter Head: Description The Slip Loc diverter adapter/attachment contains a profile for an independent and inexpensive load shoulder to be contained between the casing and the adapter. After drilling out and landing the surface casing, the Slip Loc diverter adapter can be removed and the subsequent casing head attached to the mandrel hanger. F e a t u re s a n d B e n e f i t s ◆ Seals the well bore while drilling out for surface casing. ◆ The surface hanger is landed on load shoulder. Since the casing is landed, there is no need to wait further for cement to set up. ◆ Saves rig time associated with welding on a flange to attach the diverter and with removal of the flange once the surface casing has been landed. ◆ Slip Loc diverter adapter can easily and quickly be removed after landing surface casing. The adapter can remain attached to the drilling riser system for subsequent wells. ◆ Available in 20˝ & 13-3/8˝. Other sizes can be manufactured on request.
S o c k e t - We l d L a n d i n g R i n g w i t h D i v e r t e r Q u i c k C o n n e c t : Description A diverter landing ring is welded to the drive or conductor pipe. The diverter attachment with the diverter is lowered over the neck of the adapter and locked into place. F e a t u re s a n d B e n e f i t s ◆ Seals the well bore while drilling out for surface casing. ◆ Surface hanger can be provided with or without annulus seals. ◆ The diverter attachment can be easily and quickly removed by simply backing out the bolts around the circumference of the attachment, thus saving valuable rig time. ◆ The attachment can remain on the drilling riser system for subsequent wells. ◆ Available in 26˝, 24˝, 20˝, 18-5/8˝ & 16˝. Other sizes can be manufactured on request.
Slip Loc Bottom x Diverter Adapter Head: Description The diverter adapter connector is attached to the drive or conductor pipe. Once surface casing is cemented, the connector can be removed for installation of the surface wellhead. F e a t u re s a n d B e n e f i t s ◆ Seals the well bore while drilling out for surface casing. ◆ Saves rig time associated with welding on a flange to attach the diverter and with removal of the flange once the surface casing has been landed. ◆ Slip Loc diverter adapter can easily and quickly be removed after landing and cementing surface casing. The adapter can remain attached to the drilling riser system for subsequent wells. ◆ Available in 30˝, 26˝, 24˝ & 20˝. Other sizes can be manufactured on request.
19
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DRILLING PRODUCTS
Drilling
Pr o d u c t s
Since 1927, our company has concentrated on one mission: engineering, manufacturing and supporting the finest-quality surface wellhead products and systems. Throughout the growth and expansion of global oil and gas exploration and production and the increasing sophistication and difficulty of drilling projects, FMC Energy Systems has been there responding to your requirements for safe, reliable wellhead systems designed to deliver maximum productivity while controlling costs. In the process of listening to your needs and fulfilling them with appropriate technology, we developed a line of drilling products that have become the industry's standards for safety, performance and cost-effectiveness. This section of our catalog is an introduction to our drilling product families across the board from standard API flanged casing heads to advanced wellheads for critical service, and platform, TLP/SPAR applications. With the help of this catalog and your FMC Energy Systems representative, you can identify precisely what you’ ll need for your unique application wherever in the world you’ re working, whatever your drilling environment, your well characteristics and your performance and budget parameters.
Providing products
for
optimal your
20
drilling
application
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DRILLING PRODUCTS
Casing Heads
Description: The casing head is the lowest part of the wellhead assembly and is almost always connected to the surface casing string. It supports subsequent drilling wellhead and completion equipment.
Functions ◆ Provides for attachment to surface casing string. ◆ Supports blowout preventers while hole is drilled for next casing string. ◆ Provides for suspending and packing off the next casing string. ◆ Provides outlets for annular access. ◆ Provides for testing BOPs while drilling.
C-22-EG
C-29
C-22 Bowl Features ◆ C-22 accepts C-21 non-automatic sealing casing hanger w/ type H seal ring, C-22 & C-122 automatic sealing casing hanger. ◆ C-22-BP-ET has bowl-protector lockdown screws in the top flange. ◆ C-22-EG eliminates the need for lockdown screws to retain bowl protectors. ◆ Bottom preparation can be either male-threaded, female-threaded, slip-on weld or Slip Loc. Benefits ◆ Straight bowl prevents wedge-locking of bowl protectors, casing hangers and test plugs. ◆ Seal bore less likely to be damaged during drilling. ◆ Detachable base plate available for C-22-EG heads provides time savings and adds value due to better utilization of customer-owned property. ◆ C-22-EG reduces number of leak paths, lowers cost and increases safety as there is no need to work beneath the BOPs.
C-29 Bowl Features ◆ C-29 offers same features as industry standard C-22 with the exception of the EG option. ◆ C-29-ET has multiple lockdown screws in top-flange which retain the hanger and can be used to energize the hanger packoff seal. Benefits ◆ Deeper bowl accepts C-29/C-129/C-229/C121-S extreme-load casing hangers in addition to other FMC Surface Wellhead casing hangers. ◆ The lockdown screws of the C-29-ET can also be used as bowl-protector hold-down screws.
21
22
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DRILLING PRODUCTS
Casing Heads
Description: The casing head is the lowest part of the wellhead assembly and is almost always connected to the surface casing string. It supports subsequent drilling wellhead and completion equipment.
Functions ◆ Provides for attachment to surface casing string. ◆ Supports blowout preventers while hole is drilled for next casing string. ◆ Provides for suspending and packing off the next casing string. ◆ Provides outlets for annular access. ◆ Provides for testing BOPs while drilling.
C-22-EG
C-29
C-22 Bowl Features ◆ C-22 accepts C-21 non-automatic sealing casing hanger w/ type H seal ring, C-22 & C-122 automatic sealing casing hanger. ◆ C-22-BP-ET has bowl-protector lockdown screws in the top flange. ◆ C-22-EG eliminates the need for lockdown screws to retain bowl protectors. ◆ Bottom preparation can be either male-threaded, female-threaded, slip-on weld or Slip Loc. Benefits ◆ Straight bowl prevents wedge-locking of bowl protectors, casing hangers and test plugs. ◆ Seal bore less likely to be damaged during drilling. ◆ Detachable base plate available for C-22-EG heads provides time savings and adds value due to better utilization of customer-owned property. ◆ C-22-EG reduces number of leak paths, lowers cost and increases safety as there is no need to work beneath the BOPs.
C-29 Bowl Features ◆ C-29 offers same features as industry standard C-22 with the exception of the EG option. ◆ C-29-ET has multiple lockdown screws in top-flange which retain the hanger and can be used to energize the hanger packoff seal. Benefits ◆ Deeper bowl accepts C-29/C-129/C-229/C121-S extreme-load casing hangers in addition to other FMC Surface Wellhead casing hangers. ◆ The lockdown screws of the C-29-ET can also be used as bowl-protector hold-down screws.
21
22
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Drilling P ro d u c t s
FMC SURFACE WELLHEAD BASIC FLANGED DRILLING PRODUCTS
TUBING HEAD
TCM-ET
TC-ET
TC-60-ET
TC-WD-ET
C-22-EG
C-29
C-22-BP
C-29-ET
SLICK OD/FS ID
4 FS/S
PI Seal
C-21
C-22
C-29
C-121-S
C-122
C-22-EG
C-22
C-22-BP
C-29
C-29-ET
CASING SPOOL
REDUCER BUSHING
CASING HANGER
CASING HEAD
BASE PLATE
C-129
C-229
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D C
B A
C - 2 2
A N D
C - 2 2 - B P
C A S I N G
H E A D S
Top Flange Work, Size, in.
7 7 8 8 8 8 8 8 9 9 10 10
5/8 5/8 5/8 5/8 5/8 5/8 5/8 5/8 5/8 5/8 3/4 3/4
9 9 9 9 9 11 11 11 11 11 11 11
10 11 11 13 13 13 16 16 16 20 20
3/4 3/4 3/4 3/8 3/8 3/8
11 13 13 13 13 13 16 16 16 21 20
5/8 5/8 5/8 5/8 5/8 3/4 3/4 3/4 1/4 3/4
Dimensions, In.
Pressure, psi
A
2,000 3,000 2,000 3,000 5,000 2,000 3,000 5,000 3,000 5,000 2,000 3,000
15 15 13 15 15 15 16 18 16 16 15 16
5,000 2,000 3,000 2,000 3,000 5,000 2,000 3,000 5,000 2,000 3,000
16 17 17 15 16 18 18 18 18 29 21
WHEN ORDERING
7/8 7/8 7/8 7/8 15/16 1/2 3/4 3/4 3/4 3/4 3/4 3/4 3/8 3/8 1/16 1/2 1/8 1/8 1/8 1/2 3/4
B
Weight
C
D
Lb.
Kg
8 9 8 8 9 9 9 11 9 9 9 9
11/16 5/16 9/16 9/16 5/16 1/4 3/16 1/4 3/16 3/16 1/4 13/16
7 7 8 8 8 8 8 8 9 9 10 10
8 8 8 8 8 10 10 10 10 10 10 10
3/4 3/4 3/4 3/4 3/4 7/8 7/8 7/8 7/8 7/8 7/8 7/8
210 240 180 240 250 340 460 530 430 680 300 410
95 109 62 109 113 154 209 240 195 308 136 186
9 9 9 9 9 12 10 10 10 13 13
13/16 3/8 1/4 3/8 3/8 7/8 5/8 5/8 5/8 3/8 5/16
10 11 11 12 12 12 15 15 15 19 19
10 13 13 13 13 13 16 16 16 20 20
7/8 1/2 1/2 1/2 1/2 1/2 5/8 5/8 5/8 1/8 1/8
560 460 700 380 500 750 980 995 1100 1250 1400
254 209 318 172 227 340 445 451 499 567 635
1/2 1/2 1/2 1/4 1/4 1/4 3/16 3/16
Casing Heads, specify the following:
A. FMC Energy Systems Model B. Bottom Connection 1. Male thread, female thread, slip-on weld, slip-on weld with internal seal or Slip Loc 2. Casing size C. Top Connection 1. Flange or clamp hub 2. Flange/clamp hub size 3. Flange/clamp hub working pressure
D. Side Outlets 1. Threaded, studded or flanged 2. Size 3. Working pressure E. Options 1. With or without lockdown screws 2. With or without base plate (specify conductor) F. API 6A Requirements 1. PSL 2. Temperature Class 3. Material Class 4. With or without monogram
NOTES: ◆ Type H seal rings cannot be installed in C-22-BP-ET or C-29 ET heads. ◆ The C-121-S nonautomatic-sealing casing hanger cannot be used in a C-22 bowl.
23
Casing Heads
Bottom Casing Thread Size, in.
Approximate
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DRILLING PRODUCTS
S l i p - Ty p e C a s i n g H a n g e r s
Description: Slip-type casing hangers provide a method to transfer the weight or tension load of a casing string to a casing head or spool. Slip-type hangers are available in automatic-sealing and nonautomatic-sealing varieties. Automatic hangers have seals which are energized by casing weight, while nonautomatic hangers have seals which require means other than casing weight to be energized. Nonautomatic hangers are typically used when insufficient casing load is available or when cementing back to the surface.
Functions ◆ Provides for easy wraparound or split installation at any location on the casing string. ◆ Provides for suspension of the casing load from a casing head or spool. ◆ Provides a means to center the casing string in the head or spool. ◆ Provides an annular seal.
C-22
C-29
C-22 and C-29 Features ◆ Fits all FMC Surface Wellhead C-22/C-29 casing heads and spools. ◆ Is designed to suspend typically encountered casing loads. ◆ Provides automatic packoff sealing. ◆ Only 50,000 to 60,000 pounds of casing load is normally needed to energize the annulus seal. ◆ Hangers can be lowered through blowout preventers and landed before or after cement has set. ◆ Incorporates spring-loaded latch and heavy-duty hinge. ◆ Has interlocking slip segments. Benefits ◆ Industry-standard hanger maximizes use of customer property. ◆ Off-the-shelf availability suits typical applications. ◆ Saves installation time and eliminates working in hazardous cellar conditions. ◆ Is suitable for short casing or lightly loaded applications. ◆ Provides flexibility and safety of installation. ◆ No separate screws or latches are needed, allowing for ease of installation; has rugged, extensively tested, field-proven design. ◆ Slips engage casing evenly, distributing casing load to the bowl.
24
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C-122
C-129
C-21 Hanger with Type H Seal Ring
Benefits ◆ Industry-standard hanger maximizes use of customer property. ◆ Off-the-shelf availability suits typical applications. ◆ Isolates test pressure from hanging load; suitable for short casing or lightly loaded applications. ◆ Provides flexibility and safety of installation. ◆ Offers easy installation. ◆ Slips engage casing evenly, distributing casing load to the bowl.
C-122 and C-129 Advanced-Design Hangers Features ◆ Fits all FMC Surface Wellhead C-22/C-29 casing heads and spools. ◆ Is designed to handle harsher environments and difficult applications. ◆ Has automatic packoff sealing. ◆ Only 50,000 to 60,000 pounds of casing load is normally needed to energize the annulus seal. ◆ Hangers can be lowered through blowout preventers and landed before or after cement has set. ◆ Incorporates split-bowl design with tangential bolting. ◆ Has interlocking slip segments. ◆ Incorporates patented nonextrusion plate design. Benefits ◆ Is interchangeable with C-22 and C-29 hanger profiles. ◆ Has a broader range of application. ◆ Saves installation time and eliminates working in hazardous cellar conditions. ◆ Provides flexibility and safety of installation. ◆ Offers easy installation. ◆ Slips engage casing evenly, distributing casing load to the bowl. ◆ Is capable of long-term sealing in harsher environments.
25
S l i p Ty p e Casing Hangers
Features ◆ Fits all FMC Surface Wellhead C-22/C-29 casing heads and spools. ◆ Is designed to suspend typically encountered casing loads. ◆ Has independently installed, interference-energized packoff sealing ring. ◆ Slip and bowl assembly can be lowered through blowout preventers and landed before or after cement has set. ◆ Incorporates split design with easily engaged latching cap screws. ◆ Provides interlocking slip segments.
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C-121S
C-229
C-121S Advanced-Design Hangers Features ◆ Fits FMC Surface Wellhead C-29 casing heads and spools. ◆ Is designed to handle harsher environments and difficult applications. ◆ Has a compression packoff above the slips. ◆ Offers choice of two methods to energize packoff. ◆ Hangers can be lowered through blowout preventers and landed before or after cement has set. ◆ Incorporates split-bowl design with tangential bolting. ◆ Provides interlocking slip segments. ◆ Incorporates patented nonextrusion plate design. Benefits ◆ Is interchangeable with FMC Surface Wellhead C-29 hanger profiles. ◆ Has a broader range of application. ◆ Isolates test pressure from hanging load, which allows for higher casing load/ pressure combinations. ◆ Has a versatile packoff energization. ◆ Provides flexibility and safety of installation. ◆ Offers easy installation. ◆ Slips engage casing evenly, distributing casing load to the bowl. ◆ Is capable of long-term sealing in harsher environments.
C-229 Extreme-Load Hangers Features ◆ Fits FMC Surface Wellhead C-29-ET casing heads and spools. ◆ Is designed to handle extreme load, harsher environments and difficult applications. ◆ Has packoff above the slips. ◆ Provides automatic packoff sealing. ◆ Hangers can be lowered through blowout preventers. ◆ Incorporates split-bowl design with tangential bolting. ◆ Provides interlocking slip segments. ◆ Incorporates patented nonextrusion plate design. Benefits ◆ Is interchangeable with FMC Surface Wellhead C-29-ET hanger profiles. ◆ Has a broader range of application. ◆ Isolates test pressure from hanging load, which allows for higher casing load/ pressure combinations. ◆ Saves installation time and eliminates working in hazardous cellar conditions. ◆ Provides flexibility and safety of installation. ◆ Offers easy installation. ◆ Slips engage casing evenly, distributing casing load to the bowl. ◆ Is capable of long-term sealing in harsher environments.
26
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C A S I N G Flange X Casing (Inches)
H A N G E R
C-21
C-22
9 x 4 1/2 9x5 9 x 5 1/2 11 x 4 1/2 11 x 5 11 x 5 1/2 11 x 6 5/8 11 x 7 11 x 7 5/8 13 5/8 x 5 1/2 13 5/8 x 7 13 5/8 x 7 5/8 13 5/8 x 8 5/8 13 5/8 x 9 5/8 13 5/8 x 10 3/4 16 3/4 x 9 5/8 16 3/4 x 10 3/4 16 3/4 x 11 3/4 16 3/4 x 13 3/8 18 3/4 x 9 5/8 18 3/4 x 13 3/8 20 3/4 x 9 5/8 20 3/4 x 10 3/4 20 3/4 x 11 3/4 20 3/4 x 13 3/8
X X X X X X X X X
X X X X
X X X X X
X X X X X
X X
X
X
X
X X X X X
20 3/4 x 16
X
X
X
21 21 21 21 21 26
X X
X
X X X
X X
1/4 1/4 1/4 1/4 1/4 3/4
x x x x x x
9 5/8 10 3/4 11 3/4 13 3/8 16 18 5/8
X X X X
WHEN ORDERING A. FMC Energy Systems Model B. FMC Casing Head/Spool Type C. Top Flange or Clamp-Hub Size D. Casing Size E. Casing Weight F. Casing Grade
X X X X
X X X
S E R I E S
C-29
C-121-S
C-122
C-129
X X X
X X X
X X X
X X X
X X X X X X X X X X X X
X X
X X
X X
X X X
X
X X
X
X X X
X X X
X X X
X
X
X
X
X X
Casing Hangers, specify the following: G. API 6A Requirements 1. PSL 2. Temperature Class 3. Material Class 4. With or without monogram
NOTE: ◆ Standard C-21 cannot be used in casing heads or spools that have lockdown screws.
27
C-229
X
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DRILLING PRODUCTS
Casing Spools
Description: The casing spool has a top bowl to accommodate the casing hanger. The spool also has a bottom bowl with a packoff seal and a flange or clamp hub for mounting it on top of a casing head or previous spool. Outlets are provided for annular access. Multiple casing spools may be stacked to hang intermediate and production casing strings.
Functions ◆ Provides a load shoulder in the top bowl to support a casing hanger. ◆ Provides a controlled bore in the top bowl for the casing hanger seal. ◆ Provides a seal in the bottom bowl to pack off the previous casing string and isolate flange or clamp hub seals and casing hanger seals from internal casing pressure. ◆ Provides side outlets for annular access. ◆ Provides a port for pressure-testing casing seals and flange connections. ◆ Provides for supporting and testing BOPs while drilling. ◆ Provides retention for bowl protector while drilling.
C-22-EG
C-29
C-22 Features ◆ Has a straight bowl. ◆ Accepts C-21 nonautomatic-sealing casing hanger w/type H seal ring, C-22/C-122 automaticsealing casing hanger. ◆ C-22-BP-ET has bowl-protector lockdown screws in the top flange. ◆ C-22-EG eliminates the need for lockdown screws to retain bowl protectors. ◆ Accepts FMC Surface Wellhead C-22 BOP test plugs. ◆ Bottom bowl preparations available are: -PI pressure-intensified seal -S/FS-BG Seal Bushing -SBMS II metal-to-metal seal -Integral FS seal -RCMS (Rough Casing Metal Seal) -FS-BG bushing ◆
Is available with threaded, studded or flanged outlets.
Benefits ◆ Straight bowl prevents wedge-locking of bowl protectors, casing hangers and test plugs. ◆ C-22-EG reduces number of leak paths, lowers cost and increases safety.
28
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C-29 Features ◆ Offers same features as industry-standard C-22, with the exception of the EG option. ◆ C-29-ET has multiple lockdown screws in top-flange which retain the hanger and can be used to energize the hanger packoff seal. ◆ Bottom bowl preparations available are: -PI pressure-intensified seal -S/FS-BG Seal Bushing -SBMS II metal-to-metal seal -Integral Single or Double FS seal -RCMS (Rough Casing Metal Seal) -FS-BG bushing Benefits ◆ Deeper bowl accepts C-29/C-129/C-229/C121-S extreme-load casing hangers in addition to other FMC Surface Wellhead casing hangers. ◆ The lockdown screws of the C-29-ET can also be used as bowl-protector hold-down screws. B F
H E
J
A C
G D
C A S I N G A
Seal, Bottom Flange x Top Flange 7" FS,11-5Kx11-5K SSO 8-5/8" FS, 13-5/8-3K x 11-3K SSO 9-5/8" FS, 13-5/8-3K x 11-3K SSO 8-5/8" FS, 13-5/8-3K x 11-5K SSO 9-5/8" FS, 13-5/8-3K x 11-5K SSO 8-5/8" FS, 13-5/8-5K x 11-5K SSO 9-5/8" FS, 13-5/8-5K x 11-5K SSO 8-5/8" FS, 13-5/8-5K x 11-10K SSO 9-5/8" FS, 13-5/8-5K x 11-10K SSO 10-3/4" FS, 16-3/4-3K x 11-5K SSO 13-3/8" FS, 20-3/4-3K x 13-5/8-5K SSO 13-3/8" FS, 21-1/4-2K x 13-5/8-5K SSO 9-5/8" FS, 13-5/8-5K x 13-5/8-5K
Overall Length 26.00/27.75 20.25/21.75 20.50/21.62 26.25/26.00 26.13/27.41 26.91/27.41 26.13/27.41 29.88/29.38 29.88/27.38 27.25/26.25 26.00/25.00 24.75/24.25 25.50/24.00
B C D Top Btm Bowl Restricted Bowl Dia. ID Dia. 10.880 6.375 7.130 10.880 8.020 8.770 10.880 9.005 9.780 10.880 8.020 8.770 10.880 9.005 9.780 10.880 8.005 8.77 10.880 9.005 9.780 10.880 8.020 8.770 10.880 9.020 9.780 10.880 10.020 10.917 13.505 12.520 13.568 13.505 12.520 13.568 13.505 12.520 13.568
WHEN ORDERING A. FMC Energy Systems Model B. Bottom Connection 1. Flange or Clamp Hub 2. Size 3. Working Pressure C. Top Connection 1. Flange or Clamp Hub 2. Size 3. Working Pressure
D I M E N S I O N S E F G H J Top Top Btm Depth CL Head to CL Bowl Bowl to to Face Outs Depth Depth Groove of Out 13.32/14.06 6.52 6.5 2.25 7.63/8.00 10.25/10.13 6.52 6.5 2.25 7.48/7.64 10.63/10.13 6.52 6.5 2.25 7.48/7.64 13.94/13.82 6.52 6.6 2.25 7.25/7.50 13.38/12.88 6.52 6.5 2.25 7.25/7.50 13.12/12.88 6.52 6.5 2.25 7.41/7.71 13.38/12.88 6.52 6.5 2.25 7.41/7.71 15.00/14.88 12.52 6.61 NA 10.55/10.69 15.00/14.25 12.52 6.5 NA 10.55/10.69 13.5/13.25 10.02 6.61 NA 10.10/10.16 12.62/12.38 6.52 6.5 2.25 9.44/10.34 12.38/12.12 6.52 6.61 2.25 10.22/10.38 12.88/12.12 6.52 6.5 2.25
Casing Spools, specify the following:
D. Side Outlets 1. Threaded, Studded or Flanged 2. Size 3. Working Pressure E. Options 1. With or Without Lockdown Screws 2. Bottom Seal Size and Configuration
F. API 6A Requirements 1. PSL 2. Temperature Class 3. Material Class 4. With or without monogram
NOTES: ◆ Type H Standard seal rings cannot be installed in C-22-BP-ET or C-29 ET heads. ◆ The C-121-S nonautomatic-sealing casing hanger cannot be used in a C-22 bowl.
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Casing Spools
Size
S P O O L
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DRILLING PRODUCTS
Clamps
Description: To reduce installation time and wellhead equipment size, FMC Surface Wellhead uses clamp devices in place of flange connections for wellheads. The Speedloc ® Clamp consists of a series of segments which are mechanically isolated from one another, permitting each segment to act as an independent clamp. These clamp segments pull the integral mating hubs together as the nuts are tightened. The contact surface between the segments and the hubs acts as a ramp to maximize vertical clamping force.
FMC Surface Wellhead’s integral Speedloc Clamps can be pre-installed on wellheads, BOPs and other drill-thru components with no rig assembly time required. One person can make up all sizes of Speedloc Clamps in less than 10 minutes. The increased strength and reliability of Speedloc Segmented Clamps over two-piece clamps help ensure safety in the field by greatly reducing the risk of a failure. Other factors inherent in the design of the Speedloc Clamp that help maximize personnel and rig safety include the elimination of special tools, handling devices and loose parts, minimizing time and exposure of service personnel in the area of the wellhead. FMC Surface Wellhead currently offers two versions of the Speedloc design:
Speedloc I: Proven worldwide, Speedloc® Clamps are available in nominal sizes from 7 1/16 to 21 1/4 inches for standard and sour-gas services to 20,000 psi. They provide distinct mechanical and operational advantages over alternative connectors, and are ideal for high-temperature applications. Straight-bore metal seal
Speedloc-I Segmented Clamps use FMC Surface Wellhead’s patented straight-bore metal seal (SBMS) rather than the standard API seal (R, RX or BX) found in other wellhead connectors. The SBMS seal is preloaded radially during assembly as the clamp segments pull the mating hubs together. Therefore, the Speedloc Clamp does not require further vertical preload to generate a seal. Sealing integrity is maintained by radial compression of the seal against the machine surfaces of the seal pocket. Fluctuations in vertical end loads and externally applied bending moments do not affect the function of the seal. Speedloc-I Clamps provide high bending moment and shear-resistance capacities, far exceeding conventional two-piece clamps in strength. Under well pressure conditions, the total load is distributed equally between the Speedloc-I Clamp’s studs, with only moderate torque required for full stud preload. The loss of a single Speedloc-I Clamp stud results in only 8.3% drop in clamp preload, therefore maintaining 91.7% of the installed connector’s preload. In contrast, if one stud fails on a two-piece clamp, failure of the entire clamp could occur.
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Speedloc II: Proven worldwide, Speedloc-II Clamps are available in sizes from 7 1/16 to 21 1/4 inches for standard or sour-gas services to 20,000 psi, 0oF to 250oF, providing mechanical and operational advantages over other connectors. Superior “clamping” by design
The Speedloc-II Clamp consists of a series of segments which are mechanically isolated from one another, permitting each segment to act as an independent clamp. The Speedloc II uses a travel nut with a retainer bolt to secure the segments onto the hub. When the travel nuts are being loosened, the retainer bolts keep the nuts and segments together, causing the nuts to positively retract the segments. The Speedloc-II nut threads are coated to provide a lower coefficient of friction, reducing make-up torque and dramatically increasing thread life. The result: you get enhanced clamping and higher end load capacities in a compact, preassembled design with significant safety advantages. Mates with conventional clamp hubs
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Clamps
FMC Surface Wellhead’s Speedloc-II Clamps mate to conventional clamp hubs using API RX or BX ring gaskets. The design allows for interface between FMC Surface Wellhead and existing conventional clamp hub equipment. The Speedloc II can also be provided with FMC Surface Wellhead’s straight-bore metal seal (SBMS) for special applications. Speedloc-II Clamps maximize strength by distributing total load equally between the clamp’s studs, with only moderate torque required for full preload. Speedloc-II Clamps typically have 12 or 16 studs, depending on the size, versus two or four studs in conventional clamps. As a result, the Speedloc II’s studs are smaller in diameter for the same load-bearing capacity, and require significantly less torque for installation.
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DRILLING PRODUCTS
Reducer Bushings
Description: FMC Energy Systems provide a wide variety of seals to install in bottom of Casing Spools and TC Tubing Heads to adapt them to different casing sizes. Interference-type seals with nonextrusion backup rings provide secondary seal.
SLICK OD/FS ID
4 FS/S
PI Seal
4 FS/S Features and Benefits ◆ ◆ ◆ ◆ ◆
Is standard secondary seal for all FMC Energy Systems casing spools and tubing heads. Is installed in the bottom bowl, where it is held in place by a snap ring. Utilizes two FS seals on the ID and two S seals on the OD. Is available in various ID and OD combinations to adapt casing spools and tubing heads to different casing sizes. High-pressure seal (15,000 psi working pressure).
PI Annulus Seals Features and Benefits ◆ ◆ ◆
Offers optional annulus seal. Is available in various ID and OD combinations to adapt casing spools and tubing heads to different casing sizes. High-pressure seal (15,000 psi working pressure) has nonextrusion backup rings and is secured in the bottom bowl by an acme-threaded lock ring.
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Reducer Bushings
“FMC Energy Systems service technicians have been the safety top performers since we track the ratio in our Gulf of Mexico operations.” A WORLDWIDE LEADER OIL COMPANY
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COMPLETION SOLUTIONS
T
Simple o Critical While no two completion situations and conditions are quite the same, in general, reservoir characteristics and well fluid analyses drive the design of a surface control system — whether a basic system or the most challenging completions for critical service. Your FMC Surface Wellhead sales/technical representative adds value by recommending the right completion equipment for your unique situation. In this process, we consider the economics of your well, the performance/risk factors of your application and the support services available for your well locations. To introduce our catalog of completion solutions components and systems, the following examples illustrate a progression of completion models from basic to critical service.
FMC
◆
Energy
Systems
completion
system
features
Streamlined, versatile system is based on a single, straight-bore tubing head design for maximum utilization of components.
◆
Standard components for conventional tubing completions, including single and multiple strings and completions with submersible pumps or surface-controlled subsurface safety valves, are included.
◆
Simple completion procedures keep well pressure under control at all times. All hangers can be run through BOPs, allowing well to be secured before BOPs are removed.
◆
System includes the easiest-to-run dual split hanger in the industry.
◆
Working pressure ratings are from 2,000 to 20,000 psi.
◆
Material options for H2S/CO2, fire-resistant and low-temperature service are included.
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Completion Solutions
“FMC Energy System’s engineers are our reference to know the most reliable and advanced technology in dry trees.” A NATIONAL OIL COMPANY
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COMPLETION SOLUTIONS
BASIC
SINGLE
COMPLETION
Model 100 Series Gate Valve
Developed for applications where economics are the major driver. This is achieved without compromising quality or safety. Features and Benefits ◆ Available up to 5,000 psi wells and completion sizes up to and including 3 1/8". ◆ Suitable for slightly sour and corrosive environments. ◆ Utilizes FMC Energy Systems’ proprietary interference elastomer seals and elastomer seal compound.
Continuous Control Line for subsurface safety valve Model 101 Gate Valve
Externally re-energizeable Tubing Hanger Seal
ADVANCED
SINGLE
COMPLETION
Developed for applications where production conditions are known or predictable. This concept includes FMC Energy Systems’ proprietary elastomer seals designs and our “state of the art” Model 120/130 gate valves.
Reliable and simple TC-1A tubing Hanger
Features and Benefits ◆ Available up to 15,000 psi wells and completion sizes up to 4 1/16". ◆ Suitable for sour, corrosive environments and when producing in environmentally sensitive areas or in close proximity to the densely inhabited areas (AA to FF). ◆ Production environments include oil, gas, gas lift and all flooding and injection operations when corrosion may be an issue. ◆ Available with or without control-line porting. Multiple ports are available if required. ◆ Certified to API 6A, Appendix F, PR-2 plus additional cycle testing as required by FMC Energy Systems.
Elastomeric FS seal FMC Energy Systems proprietary design
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Composite Block to reduce number of leak paths
CRITICAL SERVICE SINGLE COMPLETION
Block equipped with double master valve, tee, and swab valve
Developed for the most severe production requirements. Includes FMC Energy Systems’ patented metal-to-metal seal technology and the totally non elastomeric Model 120/130 gate valve. Features and Benefits ◆ Available up to 20,000 psi wells and completions sizes up to and including 7 1/16". ◆ Suitable for sour, corrosive environments and when producing in environmentally sensitive areas or in close proximity to the densely inhabited areas (AA to HH). ◆ Production environments include primarily highpressure and high-temperature gas production. ◆ Depending on the component, surface temperature rating can be as high as 450°F. ◆ Available with or without continuous control-line porting. Multiple ports are available if required. ◆ Utilizes FMC Energy Systems’ patented metal-to-metal sealing technology. ◆ Certified to API 6A, Appendix F, PR-2 plus additional 300 cycles as required by FMC Energy Systems. Speedloc® connection for a faster make up and to increase safety Model 130 Actuated Gate Valve
DUAL
COMPLETION
Developed for all multiple tubing string completions. The composite block can be configured where it is best suited for the Operator’s well site. Valves can be all front facing or alternate where the long string faces one direction and the short string 180° offset. Features and Benefits ◆ Available up to 10,000 psi wells and completions sizes up to and including 4 1/16". ◆ Suitable for sweet or sour, corrosive environments. ◆ Production environments include oil, gas, gas lift and all flooding and injection operations. ◆ Available with or without control-line porting. Multiple ports are available if required. ◆ FMC Energy Systems designs for minimal overall height and maximum access. This translates into costs savings and safer operating conditions for the production operators. ◆ Utilizes FMC Energy Systems’ proprietary interference and elastomer seals and elastomer seal compound. Is available with metal-to-metal sealing if required. ◆ Available in either a Speedloc®, studded, or flanged connection. ◆ Certified to API 6A, Appendix F, PR-2 plus additional cycle testing as required by FMC Energy Systems.
Straight-bore metal-to-metal tubing hanger seal
Pressureintensified seal
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ELECTRIC SUBMERSIBLE PUMP COMPLETIONS
Integral system designed to exactly match customer needs
Developed for ESP or ESPCP applications. FMC Energy Systems has standardized on penetrator options to fulfill all the Operator’s requirements without losing sight of the need to maintain a cost-effective system. Features and Benefits ◆ Available up to 5,000 psi wells and completion sizes up to and including 4 1/16". ◆ Designed for Class 1 Division 1, non-Class 1 Division 1, or simple cable packoff penetrator options. ◆ Penetrator options have been rationalized to offer flexibility and ease of installation. ◆ Suitable for sweet or sour and corrosion environments. ◆ Production environments include oil and are compatible with injection operations when corrosion may be an issue. ◆ Available with or without control-line porting. Multiple ports are available if required. ◆ Utilizes FMC Energy Systems’ proprietary interference and elastomer seals and elastomer seal compound. ◆ Certified to API 6A, Appendix F, PR-2 plus additional cycle testing as required by FMC.
Available for multiple sizes
INTEGRAL PRODUCTION BOP FOR ROD AND PROGRESSING CAVITY PUMPS
Developed for artificial lift applications for Rod Pumps and Progressing Cavity Pumps (PCP). To better serve the artificial-lift market, FMC Energy Systems has added Integral Production BOPs (IPBOP) to our product portfolio. The IPBOP allows the Operator to safely re-enter the well bore by sealing off against the rods or, if the rods are parted, allows one to blind off the well bore.
Model 100 series gate valve
Features and Benefits ◆ Available up to 2,000 psi wells and completion sizes up and including 4 1/16". ◆ Suitable for sour, corrosive environments and when producing in environmentally sensitive areas or in close proximity to the densely inhabited areas (AA to FF). ◆ Production environment is oil but can be adapted to be suitable if adjacent injection operations create a more corrosive environment. ◆ Although independent components can be provided, the Integral Production BOP (IPBOP) can integrate the tubing head bonnet, production BOP and flow tee, or any combinations of these, in one unit. ◆ The Integrated BOP offers cost savings when compared to purchasing the individual items. In addition, potential leak paths are greatly reduced, and the overall height, which can be 50% less, is safer for Production Operators. ◆ The BOP rams have the capability to seal off from 0 to 11/2" rods.
Available with multiple penetrator options
Cost-effective alignment method
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COILED
11:01 AM
TUBING
Page 6
COMPLETION
Developed to allow operators to continue production from natural-lift oil and gas wells without major workovers. FMC Energy Systems has experienced various applications of coiled tubing, including uses as initial production tubing to replace the jointed pipe, and use as a velocity string in existing completions, being snubbed into an existing well, artificial lift, gas lift, ESP completions and dual concentric strings.
Model 100 Series Gate Valve
Features and Benefits ◆ Increases savings by reducing the time the drilling rig stays on location. ◆ Minimizes the tubular cost by reducing the hole and casing sizes. ◆ Faster completion than conventional rig and jointed tubing. ◆ Prevent formation damage associated with kill fluids. ◆ Available in all popular API thread and flange connections or combinations of both. ◆ Pressure ratings are comparable to rated pressure of coiled tubing.
Bowl profile allows to land tubing string once well begins to deplete
Well is produced through suspended casing
TUBING-LESS COMPLETION / FRAC FLOW SYSTEM Model 100 Series Gate Valve
Developed to support well fracturing operations in today’s natural gas completion processes. In addition, the system works well for applications where high production rates deplete rapidly and a siphon string is to be added at a later date to further enhance production. The smaller tubing head flange allows for economical temporary tubingless completions and for traditional tubing completions. This type of completion eliminates the need for wellhead isolation tools and tree savers during the well fracturing job, saving time and money. The system supports standard jointed tubing or coiled tubing completions. Features and Benefits ◆ Available up to 15,000 psi wells. ◆ Suitable for sour, corrosive environments and when producing in environmentally sensitive areas or in close proximity to the populous (AA to HH). ◆ Eliminates the need for Wellhead Isolation tools and Tree Savers reducing rental tool cost. ◆ Reduces fracturing stack rental costs because of the smaller size. ◆ Allows a siphon string to be run through the XT, landed, and packed off. The bigger-bore XT can then be removed and replaced with a more economical tree compatible with tubing size and production pressures of the flowing well. ◆ Also available for use with the DTO Wellhead System providing additional drilling time and completion savings.
Siphon String head for temporary or permanent coiled tubing installation
Retractable load shoulder to allow Head full opening
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H O R I Z O N TA L
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Angled flow to reduce erosion
COMPLETION
Developed to allow well intervention to occur without removing the XT and flowline. This allows the Operator to maintain flowline connections, thus, reducing cost associated with reconnecting the well and enabling the well to be brought back onstream quicker. Features and Benefits ◆ Available up to 10,000 psi wells and completion sizes up to and including 9". ◆ Suitable for sour, corrosive environments and when producing in environmentally sensitive areas or in close proximity to the densely inhabited areas (AA to HH). ◆ Production environments include oil, gas and gas lift. ◆ Greatly simplifies access to the tubing string for workovers. ◆ Provides easier access for the Production Operator to the gate valves. ◆ On bigger-bore completions, can greatly reduce height required for the wellhead deck. ◆ Available with or without control-line porting. Multiple ports are available if required. ◆ Utilizes FMC Energy systems’ proprietary interference elastomer seals and elastomer seal compound and our patented metal-to-metal seal technology. ◆ Certified to API 6A, Appendix F, PR-2 plus additional cycle testing as required by FMC Energy Systems.
Fire-resistant block with eutectic device allows metal-to-metal backseat in fire situation
Speedloc® connection for a faster make up and to increase safety
Allows tubing vertical access
LARGE-BORE
COMPLETION
Developed for higher-volume flow rates and applications where erosion due to those flow rates might be an issue. This concept employs FMC Energy Systems’ latest technology in metal and elastomer seals and the Model 120/130 gate valve.
Allows to land casing and tubing without nippling down the tree
Features and Benefits ◆ Available up to 15,000 psi wells and completions sizes up to and including 7 1/16". ◆ Suitable for sour, corrosive environments and when producing in environmentally sensitive areas or in close proximity to the densely inhabited areas (AA to HH). ◆ Production environments include primarily highpressure and high-temperature gas production. ◆ Depending on the component, surface temperature rating can be as high as 450oF. ◆ Available with or without continuous control-line porting. Multiple ports are available if required. ◆ Utilizes FMC Energy Systems’ patented metal-tometal sealing technology. ◆ Certified to API 6A, Appendix F, PR-2 plus additional 300 cycles as required by FMC Energy Systems.
Production bore
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CONVEYED
ESP
Developed to allow the submersible pump to be retrieved with minimal well intervention and with a coiled tubing unit. The well is produced out of the annulus; thus, the flowline stays intact during any well intervention. A recognized disadvantage of ESPs is inherent maintenance that is required on any downhole pump. This design concept allows the maintenance to occur in a fraction of the time with conventional ESP completion methods. Features and Benefits ◆ Ability to retrofit existing wells and new well drills. ◆ Continuous flowline connection with BOP intervention. ◆ Complete well serviceability under “live well” conditions. ◆ Isolation of electrical cable and cable splice. ◆ Quick workover and recompletion connections.
Metal-to-metal tubing hanger seal
Integral bottom master and tubing head adapter
Adjustable mandrel hanger
Class 1 Division 1 Penetrator
TLP/SPAR
COMPLETION
Developed to provide a dry tree access to a subsea wellbore from a tension leg platform (TLP) and SPAR.
Allows pump retrieving with a coiled tubing unit
Features and Benefits ◆ Single and dual casing riser design standards for all top tension riser applications. ◆ Available up to 15,000 psi wellhead and completion sizes up to 7 1/16". ◆ Fatigue-resistant length adjustment hangers and riser joints for accurate and fast riser hang off. ◆ High bending moment capacity Speedloc® clamp connections that can handle the rigors of deepwater dry completion units. ◆ Riser load measurement capability that allows simple installation and maintenance. ◆ Compact designs that minimize weight and height for the tight well spacing and riser weight restrictions of deepwater dry completion units. ◆ Use of intermediate pressure rated valves (6,650 psi) for weight savings. ◆ Multiple ports and continuous control lines. ◆ Utilizes FMC Energy Systems’ patented metal-tometal seal technology. ◆ Integral design of access platforms allow for safe personnel access in tight space conditions.
Model 100 Series Gate Valve
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COMPLETION PRODUCTS
P
Completion roducts For over 75 years, from the early days of oil and gas production, our company has concentrated on one vital mission: designing, manufacturing and supporting wellhead completion systems of the highest quality. Throughout the growth and expansion of the global oil and gas industry and the increasing sophistication and difficulty of production programs, FMC Energy Systems has been there, responding to your requirements for safe, reliable completion systems designed to deliver maximum productivity while controlling costs. In the process of listening to your needs and fulfilling them with appropriate technology, we developed a line of completion products that have become the industry's standards for safety, performance and cost-effectiveness. This section of our catalog is an introduction to our surface wellhead completion product family, from basic to critical service and platform, TLP and SPAR applications. With the help of this catalog and your FMC Energy Systems representative, you can identify precisely what you'll need for your unique application wherever in the world you're working, whatever the environment, well characteristics and fluid analyses, and your performance and budget parameters.
Providing products
optimal for
your
42
completion application
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COMPLETION PRODUCTS
Tu b i n g H e a d s
Description: The tubing head is the top spool on a surface wellhead assembly. It is installed after the last casing string to provide a load shoulder to support the tubing string and a seal bore for the tubing hanger or production casing/tubing annulus seal. When the well is completed, the tree is installed on top of the tubing head with a tubing head adapter.
Functions ◆ Provide a load shoulder inside the head to support tubing hangers and packoffs. ◆ Provide a controlled bore against which the hanger or packoff can seal. ◆ Provide for a secondary annulus seal around the top of the previous casing string. (See Bottom-Bowl Packoffs in this section.) ◆ Provide access to the annulus between the tubing string and the production casing. ◆ Provide a means to support and test BOPs while completing the well.
TC-Series Tubing Heads FMC TC-Series tubing heads have a straight-bore profile which is compatible with all FMC singleand multiple-string tubing hangers and packoffs. These heads are available in four basic styles; the only functional difference between the styles is the number and type of aligning pins, which are used to align multiple-string or specialty tubing hangers.
Features ◆ Has a straight-bore design compatible with all TC-Series tubing hangers. ◆ All TC-Series tubing heads with a 9-inch or larger top flange also accept the FMC C-29 casing hanger for casing completions. ◆ Valve removal (VR) threads are standard on all flanged or studded outlets. Benefits ◆ “Wedge locking” of bowl protector, BOP test plugs and tubing hangers is eliminated. ◆ Seal bore is less likely to be damaged during drilling. ◆ Straight bore is more economical to recondition after abandonment.
TCM-ET
TCM-ET The TCM-ET tubing head has no aligning pins. It is compatible only with single-string TC-Series tubing hangers and packoffs. The TCM can be upgraded to a TC-60-ET or TC-ET head by adding the necessary aligning pins at an FMC Energy Systems facility.
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COMPLETION PRODUCTS
Tu b i n g H e a d s
Description: The tubing head is the top spool on a surface wellhead assembly. It is installed after the last casing string to provide a load shoulder to support the tubing string and a seal bore for the tubing hanger or production casing/tubing annulus seal. When the well is completed, the tree is installed on top of the tubing head with a tubing head adapter.
Functions ◆ Provide a load shoulder inside the head to support tubing hangers and packoffs. ◆ Provide a controlled bore against which the hanger or packoff can seal. ◆ Provide for a secondary annulus seal around the top of the previous casing string. (See Bottom-Bowl Packoffs in this section.) ◆ Provide access to the annulus between the tubing string and the production casing. ◆ Provide a means to support and test BOPs while completing the well.
TC-Series Tubing Heads FMC TC-Series tubing heads have a straight-bore profile which is compatible with all FMC singleand multiple-string tubing hangers and packoffs. These heads are available in four basic styles; the only functional difference between the styles is the number and type of aligning pins, which are used to align multiple-string or specialty tubing hangers.
Features ◆ Has a straight-bore design compatible with all TC-Series tubing hangers. ◆ All TC-Series tubing heads with a 9-inch or larger top flange also accept the FMC C-29 casing hanger for casing completions. ◆ Valve removal (VR) threads are standard on all flanged or studded outlets. Benefits ◆ “Wedge locking” of bowl protector, BOP test plugs and tubing hangers is eliminated. ◆ Seal bore is less likely to be damaged during drilling. ◆ Straight bore is more economical to recondition after abandonment.
TCM-ET
TCM-ET The TCM-ET tubing head has no aligning pins. It is compatible only with single-string TC-Series tubing hangers and packoffs. The TCM can be upgraded to a TC-60-ET or TC-ET head by adding the necessary aligning pins at an FMC Energy Systems facility.
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Completion P ro d u c t s
FMC SURFACE WELLHEAD BASIC FLANGED COMPLETION PRODUCTS
TREE CAP
B-15-A
B - 1 1 - AO
MODEL 101
MODEL 120/125
B - 1 1 - AO W / OT I S U N I O N
VALVES
M O D E L 1 3 0 / 1 3 5 / 1 5 0 M O D E L 1 3 0 / 1 5 0 V LT
MODEL 160
TUBING HEAD ADAPTER
Basic Adapter
A-4
A-4-D
A-3-EC/QCI
A-4-M
B-2-S
BO-2
TUBING HANGER TC-1A
TC-1W
TC-1A-EN
TC-1A-ENS
TC-1A-EMS
BO-2
BO-10
TC-B-EC
TC-2C W/DHCV
TC-60
TCM-ET
TC-ET
TC-60-ET
TC-WD-ET
TUBING HEAD
TC-1A-EMS W/XEMS
BO-10
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TC-ET
Page 6
TC-60-ET
TC-WD-ET
TC-ET The TC-ET tubing head has one aligning pin and accepts all TC-Series tubing hangers and packoffs except the TC-60 dual-split hanger. It can be upgraded to a TC-60-ET by adding two aligning pins at an FMC Energy Systems facility.
The TC-60-ET is the most versatile tubing head in the oilfield. It has three aligning pins and is compatible with all TC-Series tubing hangers and packoffs, including the TC-60 dual-split hanger. When last-minute completion changes are possible, the T-60-ET is a good investment because no shop modification is needed to adapt it to any type of tubing completion.
TC-WD-ET The TC-WD-ET tubing head has an internal wedge that is used for alignment on specific TC-Series tubing hangers. This particular design allows for alignment of multiple-string tubing hangers without external manipulation methods. TC-WD-ET tubing hangers are generally considered specific to particular customers’ requirements and can be run only in the TC-WD-ET tubing head. FMC hangers that normally are aligned with pins (TC or TC-60 type) will not function in the TC-WD-ET head.
A l t e r n a t i ve Tu b i n g H e a d C o n f i g u r a t i o n s Bottom Connections Bolt-through flange, studded flange and clamp-hub connections are available. The type and pressure rating used must match the top flange of the previous casing spool or crossover flange. Bolt-through flange connections are the most popular and economical type of connection in certain parts of the world. Clamp-hub connections are sometimes specified, because they are much faster to make up and because they reduce the diameter and weight of the assembly when space limitations are present.
Top Connections FMC Surface Wellhead tubing heads have either bolt-through flange or clamp-hub top connections, which are compatible with all FMC tubing head adapters. The producing pressure of the well normally determines the pressure rating of the top connection.
Lockdown Screws Most FMC Surface Wellhead Series tubing heads have a series of lockdown screws in the top flange (unless customer or application requires otherwise). These lockdown screws have three functions: ◆ to actuate compression-type hanger or packoff seals ◆ to lock down the hanger or packoff to prevent movement caused by thermal expansion of the tubing string during production ◆ to lock down the hanger in the event of annulus pressure NOTES: ◆
Where customer preferences or applications do not allow the use of lockdown screws, internally locking mechanisms are utilized. See section on Completion Solutions.
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Tu b i n g H e a d s
TC-60-ET
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A l t e r n a t i ve Tu b i n g H e a d C o n f i g u r a t i o n s Bottom-Bowl Packoffs (secondary seals) Tubing head bottom-bowl packoffs are used to seal around the production casing stub in the bottom bowl of the tubing head. They are often referred to as “secondary seals.” The various packoff types are described below:
Double FS Seals This design consists of two elastomeric-shaped seals located in grooves in the bottom of the tubing head. A seal is achieved by interference of the seal with the outside diameter of the casing and the bottom or OD of its retaining groove. A spring molded in each inside corner of the seal provides an anti-extrusion mechanism when sealing against pressure by bridging the gap between the tubing outside diameter and casing head seal bore. The shape of the seal allows it flexibility to maintain sealing interference with the large variations in tubing outside diameter.
PI Seals These seals consist of a T-cap seal element, nonextrusion rings and a receiver ring. These components will fit the HPE bottom prep configuration. The PI seal is designed for use up to 15,000 psi working pressure and temperatures up to 75 o F or as low as -50 o F, depending on the elastomer selected. It provides the proper compression and squeeze even with the larger API casing tolerances. The design effectively intensifies the annulus pressure and thus the internal stress in the elastomer to minimize the effects of explosive decompression.
SBMS-II Seals This metal-to-metal seal consists of a “U”-shaped ring with a “bump” sealing surface at the outside and inside legs of the “U.” When installed, the entry ramp compresses the legs of the “U” inward and creates contact stress in each “bump” that provides the seal. This seal requires the casing stub OD to be field machined after the casing is hung to provide the proper sealing tolerances and surface finish. This is accomplished with a portable pneumatic-driven tool. It is good for temperatures ranging from -75 o F to 1200 o F.
RCMS Seals The Rough Casing Metal Seal (RCMS) is designed to use up to 20,000 psi. This seal does not require special machining of the casing stub; is compatible with temperatures from -20 o F to 350 o F in corrosive environments; does not require special installation tools and is simple to install; is NACE compatible; is compatible with casing spool and tubing spool strength; is compatible with casing string strength properties. NOTES: ◆ TC-Series packoffs are usually installed in the tubing head prior to shipment. FMC tubing heads are also available with threaded bottom preparations in some sizes and pressure ratings.
WHEN ORDERING
Tu b i n g H e a d s , s p e c i f y t h e f o l l o w i n g :
A. FMC Energy Systems Model B. Bottom Connection 1. Flanged, studded, Speedloc® clamp, clamp hub 2. Size 3. Working pressure C. Top connection 1. Flanged, studded, Speedloc® clamp, clamp hub 2. Size 3. Working pressure
D. Side Outlets 1. Threaded or studded 2. Size 3. Working pressure 4. Number of aligning pins E. Service 1. Regular or H2S F. Options 1. Type of secondary seal 2. Casing sizes
Available to meet all appropriate API-6A requirements.
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D C
B A
T C - S E R I E S Bottom Flange Size, In.
WP, psi
Top Flange Size, In.
WP, psi
T U B I N G
H E A D S
Bottom Outlets
Dimensions, In.
Prep.
A
B
Approx. Weight
C
D
Lb.
Kg 159
9
2,000
7-1/16
2,000
2-in. LPO
7 BL
18-7/8
10-9/16
6-13/16
7
350
9
2,000
7-1/16
2,000
2 1/16-in./2000 FLG
7 BL
18-7/8
10-9/16
7-13/16
7
355
161
9
2,000
7-1/16
3,000
2-in. LPO
7 BL
20-1/4
9-3/8
6 7/8
7
400
181
9
2,000
7-1/16
3,000
2 1/16-in./5000 FLG
7 BL
20-1/4
9-3/8
6-3/8
7
405
184
9
3,000
7-1/16
3,000
2-in. LPO
7 BL
21-1/4
10-1/4
6-3/8
7
500
227
9
3,000
7-1/16
3,000
2 1/16-in./5000 FLG
7 BL
21-1/4
10-1/4
6-3/8
7
505
229
9
3,000
7-1/16
5,000
2 1/16-in./5000 FLG
7 BL
22-3/8
11-3/4
6-3/8
7
665
302
11
2,000
7-1/16
2,000
2-in. LPO
9 BL
18-7/8
10-9/16
6-13/16
7
440
200
11
2,000
7-1/16
2,000
2 1/16-in./2000 FLG
9 BL
18-7/8
10-9/16
6-13/16
7
440
200
11
2,000
7-1/16
3,000
2-in. LPO
9 BL
20-3/4
10
6-3/8
7
550
249
11
2,000
7-1/16
3,000
2 1/16-in./5000 FLG
9 BL
20-3/4
10
6-3/8
7
555
252
11
3,000
7-1/16
3,000
2-in. LPO
9 BL
20-7/8
15-1/16
6-13/16
7
600
272
11
3,000
7-1/16
3,000
2 1/16-in./5000 FLG
9 BL
20-7/8
10-1/16
6-13/16
7
600
272
11
3,000
7-1/16
3,000
2 1/16-in./5000 FLG
9 BL
22-3/8
11-3/4
6-13/16
7
670
304
11
5,000
7-1/16
5,000
2 1/16-in./5000 FLG
9 BL
24-4/9
11-1/16
6-13/16
7
880
399
11
5,000
7-1/16
10,000
1 13/16-in./10,000 FLG
9 BL
26-1/2
14-5/8
6-13/16
7
856
388
11
10,000
7-1/16
10,000
1 13/16-in./10,000 FLG
9 BL
26-4/9
12-3/4
6-3/4
7
1318
598
11
10,000
7-1/16
15,000
1 13/16-in./10,000 FLG
9 HPE
26-1/2
12-13/16
6-3/8
7
1384
628
11
3,000
9
3,000
2 1/16-in./5000 FLG
9 BL
22-3/8
11-3/4
6-13/16
8-1/4
755
342
11
3,000
9
5,000
2 1/16-in./5000 FLG
9 BL
23-1/4
11-5/8
8-1/4
8-3/4
805
365
11
5,000
9
10,000
1 13/16-in./10,000 FLG
9 BL
24-1/4
13-3/8
8-1/4
8-3/4
1249
567
11
10,000
9
10,000
1 13/16-in./10,000 FLG
9 BL
28
14
7
8-3/4
1700
771
13-5/8
2,000
7-1/16
2,000
2-in. LPO
9 BL
20-3/4
10
6-13/16
7
490
222
13-5/8
2,000
7-1/16
2,000
2 1/16-in./2000 FLG
9 BL
20-3/4
10
6-13/16
7
495
225
13-5/8
2,000
7-1/16
3,000
2-in. LPO
9 BL
20
6-3/8
7
620
281
13-5/8
2,000
7-1/16
3,000
2 1/16-in./5000 FLG
9 BL
20
13-5/8
3,000
7-1/16
3,000
2-in. LPO
9 BL
24-3/8
9-1/2 9-1/2 11-1/2
6-3/8
7
625
284
6-13/16
7
675
306
13-5/8
3,000
7-1/16
3,000
2 1/16-in./5000 FLG
9 BL
24-1/8
11-1/2
6-13/16
7
670
304
13-5/8
3,000
7-1/16
5,000
2-in. LPO
9 BL
24-1/4
11-3/4
6-13/16
7
800
363
13-5/8
3,000
7-1/16
5,000
2 1/16-in./5000 FLG
13-5/8
2,000
9
2,000
2-in. LPO
9 BL 10-3/4 BL
24-1/4
11-3/4
6-13/16
7
805
365
22
10-3/8
8-1/4
8-3/4
500
227
13-5/8
2,000
9
2,000
2 1/16-in./2000 FLG
10-3/4 BL
22
10-3/8
8-1/4
8-3/4
505
229
13-5/8
2,000
9
3,000
2-in. LPO
10-3/4 BL
20
9-1/2
8-1/4
8-3/4
650
295
13-5/8
2,000
9
3,000
2 1/16-in./5000 FLG
10-3/4 BL
20
9-1/2
8-1/4
8-3/4
655
297
13-5/8
3,000
9
3,000
2-in. LPO
10-3/4 BL
22-3/4
10-9/16
8-1/4
8-3/4
700
318
13-5/8
3,000
9
3,000
2 1/16-in./5000 FLG
10-3/4 BL
22-3/4
10-9/16
8-1/4
8-3/4
705
320
13-5/8
3,000
9
5,000
2-in. LPO
10-3/4 BL
23-5/8
11-5/8
8-1/4
8-3/4
710
322
13-5/8
3,000
9
5,000
2 1/16-in./5000 FLG
10-3/4 BL
23-5/8
11-5/8
13-5/8
3,000
11
5,000
2 1/16-in./5000 FLG
10-3/4 BL
22
12-1/2
13-5/8
5,000
11
10,000
1 13/16-in./10,000 FLG
9-5/8 BL
28-15/16
13-5/8
5,000
11
10,000
1 13/16-in./10,000 FLG
9-5/8 OO
28-15/16
47
8-3/4
715
324
10
8-1/4
10-7/8
1239
562
14-11/16
9
10-7/8
1754
796
14-11/16
9
10-7/8
1754
796
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COMPLETION PRODUCTS
Tu b i n g H e a d A d a p t e r s Description: The tubing head adapter provides a transition between the Christmas tree and the tubing head. The bottom adapter connection matches the tubing head, and the top adapter connection matches the tree. Tubing head adapters are available for all types of single- and multiple-string completions, including those using electric submersible pumps, packers, downhole control valves and gas lift valves. These adapters come with threaded, flanged or studded-flanged top connections. Most tubing head adapters are available with hydraulic supply inlets for downhole control lines. If the customer requires, FMC Surface Wellhead also supplies various types of adapters that will accommodate continuous control-line capabilities. Following you will find the most generally used.
Basic Adapters A4
Dual-Seal Bore Adapters A-4-D
Single-Seal Bore Adapter A4
ESP Adapter
Basic Adapters They provide only a transition between the tubing head and the tree. These adapters do not hang the tubing or provide a controlled seal bore. Basic tubing head adapters have a smooth seal bore and are used when tubing is suspended from the tubing hanger. They are designed for low-pressure completions where downhole line or tubing strings manipulation are not required. The basic adapter is normally installed with the tree after tubing is run.
Features and Benefits ◆ Simple transition piece between the tubing head and the tree ◆ Used with a TC-1A tubing hanger ◆ Available with threaded, flanged or studded top connection
Seal Bore Adapters Seal bore adapters have the inside diameter machined to provide a controlled seal bore for an extended-neck tubing hanger or a seal nipple. They are available with a test port and/or a hydraulic supply inlet for downhole control lines. Like basic adapters, they are normally installed with the tree.
Features and Benefits ◆ Provides a seal bore for the TC-1A-ENS extended neck (Single-Seal Bore) ◆ Provides seal bores for the seal nipples on dual-completion tubing hangers (Dual-Seal Bore) ◆ Available with SCSSV control line inlets ◆ Studded top connection only
ESP Adapters ESP adapters have seal bores to accommodate both a tubing hanger neck seal and an electrical power feed-thru device. Standard ESP adapters are equipped with rotating flanges to mate to the tubing head, minimizing concerns over alignment issues. Positive alignment can be obtained through the use of optional features in the mating ESP hanger. ESP adapters can be supplied to match standard tubing heads rated to 3,000 and 5,000 psi working pressure.
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Features and Benefits ◆ Provides sealing bore for a variety of electrical feed-thru configurations, including penetrators, cable packoffs and continuous feed-thru penetrator mandrels. ◆ Provides reliable seal bores for tubing hanger neck or seal sleeves. ◆ Provides rotating attachment flange for ease of alignment to ESP hanger and tubing head flange.
Tubing Suspension Adapter B-2-S
Tubing Coupling Adapter BO-2
Tubing Coupling Adapter BO-10
Tubing Suspension Adapters These adapters provide a means to hang the tubing via tubing threads machined in the lower-connection inside diameter. The tubing threads can be used to suspend tubing when an operator wants to reciprocate tubing, but does not require a back-pressure valve in the tubing hanger. These adapters do not provide a seal. They are normally used on low-pressure completions with a wraparound packoff or stripper.
Coupling Adapters Coupling adapters provide a means to suspend the tubing in conjunction with a special coupling. They provide a lower connection for the tubing head and an upper connection for the tree and are used with a tubing coupling, which suspends the tubing and accepts a back-pressure valve. It is used for high-pressure completions where the operator wants to manipulate tubing through a wraparound packoff or stripper and needs a back-pressure valve and/or a hydraulic supply inlet for downhole control lines. An ACME thread is machined into the adapter’s bottom inside diameter to be utilized in conjunction with the coupling to hang the tubing. Then it can be screwed onto the coupling. When a tree is trimmed for critical service, a coupling adapter with a coupling nut is available to prevent possible galling of threads between the adapter and coupling on makeup.
BO-2 Coupling
BO-10 Coupling
Features and Benefits ◆ Used with the BO-2 tubing coupling ◆ Adapter makes up to the tree. ◆ Entire assembly is installed by rotating it onto the coupling. ◆ Studded top connection only
Features and Benefits ◆ Used in conjunction with the BO-10 coupling ◆ Installs without rotation of the tree ◆ Studded top connection only
WHEN ORDERING A. FMC Energy Systems Model B. Bottom Connection 1. Flanged, studded or clamp hub 2. Size 3. Working pressure
tubing head adapters, specify the following:
C. Top Connection 1. Flanged, studded, male thread or female thread D. Single or Dual Completion E. Tubing Size(s) F. Tubing Thread(s)
49
G. With/Without SCSSV Control Line Port(s) H. Service: Regular or H2S I. Material Class Available to meet all appropriate API-6A requirements.
Tu b i n g H e a d Adapters
Features and Benefits ◆ For use with the TC-1W, these adapters have tubing threads to suspend the tubing string ◆ Available top connections are male thread, female thread or studded.
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COMPLETION PRODUCTS
Tu b i n g H a n g e r s
Description: Tubing hangers are installed in the top bowl of a tubing head. Tubing hangers both suspend tubing and provide a primary annulus seal between the tubing and production casing. Hangers are run through the blowout preventers and are landed in the top bowl of the tubing head. Tubing hangers are available for any type of tubing completion. Tubing hangers also act as a means to access and manipulate additional smaller tubing lines that are utilized downhole and extended to the surface on the outside of the tubing string or strings. Packoffs allow tubing string manipulation for setting packers or displacing fluid while sealing the annulus between the tubing and the production casing.
FMC Surface Wellhead TC-Series tubing hangers are available for any type of single- or multiplestring tubing completion, including those requiring packers, subsurface safety valves, gas-lift valves and electric submersible pumps. All FMC Surface Wellhead hangers can be run through the blowout preventers, allowing the well to be secured before the preventers are removed. Most TC-Series tubing hangers accept a back-pressure valve, which seals the tubing bore. These BPV profiles may be of FMC Surface Wellhead design or they may be of another manufacturer’s design, depending upon the customer’s requirements. Some hangers are ported for hydraulic control lines, downhole safety valves or other equipment as required by the customer.
S i n g l e - S t r i n g Tu b i n g H a n g e r s Most TC-Series single-string hangers do not require aligning pins and are compatible with any TCSeries tubing head. Generally speaking, alignment pins will not be required unless there is a need to orient a hanger a particular way. An example of this might be when an additional line is being run with the tubing string and needs to be ported through a particular position in the tubing spool.
TC-1A
TC-1W
TC-1A The TC-1A is a threaded tubing hanger with an integral compression-type annulus seal that is actuated by string weight and or by lockdown screws. This hanger is also known as a threaded mandrel-type hanger and is considered one of the most basic and least expensive hangers in FMC Surface Wellhead’s TC product line.
TC-1W The TC-1W is a split, wraparound packoff that allows tubing-string manipulation to displace fluid while maintaining complete control of annular pressure. Like all TC-Series packoffs, tubing string weight must be suspended from a tubing suspension adapter or coupling adapter. The TC-1W has a compression-type seal which is actuated by lockdown screws.
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Features and Benefits ◆ Used where downhole control lines or tubing manipulation are not required. ◆ Fits all TC-Series tubing heads. ◆ Interference-type annulus seals instead of compression-type seals for 5,000 psi working pressures or below. ◆ Back-pressure-valve preparation for “ISA” (unless otherwise specified).
TC-1A-EN
TC-1A-ENS
TC-1A-EMS W/XEMS
TC-1A-EN Threaded hanger with an extended neck with interference-type seals that provide a secondary annulus seal to isolate flange and ring gasket from well pressure and fluids. ◆ Accepts control lines and injection tubing. ◆ Either interference-type seal rings or compression-type packoff (actuated by lockdown screws). ◆
Accepts FMC back-pressure valve and tree test plug.
TC-1A-ENS
Features and Benefits ◆ Extended-seal neck with interference-type seals isolates the tubing head/adapter connection from well pressure and provides for control-line porting if required. ◆ FMC Surface Wellhead “ISA” back-pressure valve preparation is standard. ◆ Interference-type annulus seals instead of compression-type for 5,000 psi working pressure or below. ◆ Has porting for SCSSV control lines, chemical injection, etc.
TC-1A-EMS W/XEMS The TC-1A-EMS is a threaded mandrel-type tubing hanger with an Externally Energized Metal (XEMS) annular seal energized with lockdown screws. The extended neck of the tubing hanger assembly is sealed at the top by the FMC Straight-Bore Metal Seal (SBMS), completing the full metal seal capability. This hanger is available with an external ACME landing thread or with internal landing thread.
Features and Benefits ◆ Available with external Acme landing thread or internal landing thread. ◆ Continuous SCSSV control and/or inhibitor line; eliminates interruptions in the line and requires neither elastomer seals nor hanger orientation. ◆ Provides back-pressure valve preparation for FMC “ISA.” ◆ Has elastomer annular seal.
51
Tu b i n g H a n g e r s
The TC-1A-ENS is a threaded mandrel-type tubing hanger with an extended neck. This hanger utilizes “S”-type seals on its neck that are used to seal inside the tubing head adapter that will be installed directly above the hanger upon completion of the well. Additionally, this hanger is provided with compression-type seals on the body that generally incorporate wire mesh-type non-extrusion devices above and below the seal. Lockdown screws are used.
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BO-2 Coupling
Page 13
BO-10 Coupling
TC-B-EC
BO-2 Coupling A BO-2 coupling-type tubing hanger uses a one-piece coupling that is externally threaded with a coarse heavy-duty ACME thread. Internally the coupling will provide tubing threads in the top and bottom along with a back-pressure valve groove. The BO-2 coupling is attached to the last tubing joint and is run in conjunction with a TC-1W wraparound-type packoff. Ultimately, the BO-2 coupling is made up into a BO-2 adapter that is assembled on the bottom of the Christmas tree.
Features and Benefits ◆ Threaded coupling is used in conjunction with the BO-2 tubing head adapter for high-pressure completions requiring both string manipulation with BOP protection and SCSSV control lines. ◆ Requires a TC-1W wraparound annulus seal. ◆ FMC Surface Wellhead “ISA” back-pressure valve preparation is standard.
BO-10 Coupling The BO-10 coupling-type tubing hanger is generally utilized on completions demanding higher completion shut-in pressures. This hanger is a coupling by design but also incorporates a separate rotating, ACME-threaded locking nut. This design is also attached to the last tubing joint, and is run in conjunction with a TC-1W wraparound-type packoff. Ultimately, the BO-10 coupling is made up into a BO-10 adapter that is assembled on the bottom of the Christmas tree.
Features and Benefits ◆ Coupling nut allows the BO-10 coupling to be installed without rotation of the tree, making it the choice for heavy trees or where dissimilar metals could cause galling problems. ◆ Requires a TC-1W for annulus seal.
TC ESP The TC ESP hanger is dual-ported, with one port designed to accept a single production tubing string. The second port is designed to accommodate the electrical conductors that pass the current between the surface cable and the subsurface cable that goes to the pump. The TC ESP hanger is designed for 7 1/16"- 3,000/5,000 and 11"- 3,000/5,000 flange sizes. We standardized on EUE thread configurations. Nevertheless, additional thread profiles and different configurations can be supplied. While configurations and designs may differ with customer requirements, the basic design concepts stay the same.
Features and Benefits ◆ Has redundant “B” Type “S” seals on the body of the hanger. ◆ No alignment groove. It has an attachable alignment plate on the bottom of the hanger when alignment is required. ◆ No threads for penetrator makeup. Penetrator will be equipped with a “jam” nut on the bottom of the penetrator to hold in the hanger body.
Benefits ◆ Can easily convert an existing flowing well to an ESP without the need to change out the tubing head. Can utilize a TCM-type tubing head. ◆ Can convert a finished hanger with a QCI penetrator profile to accept a BIW penetrator.
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Penetrator does not require rotation for makeup. Eliminates the potential of seal or thread damage when rotation of penetrator is necessary.
Multiple-String Tubing Hangers and Packoffs TC-Series multiple-string hangers and packoffs permit the independent suspension and sealing of multiple-tubing strings, allowing simultaneous production or injection to or from separate zones. They require one or two aligning pins in the tubing head bowl and are compatible with either TC or TC-60 tubing heads. The TC-60 split-type hanger may be run only in the TC-60 tubing head.
TC-60 Dual-Split Hanger
TC-2C
TC-60 Dual-Split Hanger The TC dual-split hanger is an easy-to-run split hanger with an integral compression-type packoff. The packoff seal is actuated by lockdown screws before the blowout preventers are removed. No plastic injection is required. With the TC-60 dual-split hanger, tubing strings can be run and pulled independently, allowing maximum clearance for gas-lift or subsurface safety valves. Each segment accepts a back-pressure valve and is available with control-line preparations for surface-controlled subsurface safety valves.
Features ◆ Allows tubing string to be run and pulled independently. ◆ Provides for maximum clearance for gas-lift valves, SCSSV and packers. ◆ FMC Surface Wellhead “ISA” back-pressure-valve preparation in each hanger half is standard. ◆ Tubing head must have the dual TC-60 aligning pins.
TC-2C Dual Completion ◆
Has threaded, coupling-type multi string hanger. Allows tubing strings to be run separately or simultaneously; tubing can be rotated to manipulate packers. ◆ Each accepts a back-pressure valve. ◆ Annulus and sleeve seals are interference-type. ◆ Tubing head must have the single aligning pin. ◆
Hydraulic Control-Line Preparation The TC-1A-EN tubing hanger and the TC-60 dual-split-type tubing hangers are available with hydraulic control line ports for surface-controlled subsurface safety valves or injection tubing. The TC-1W packoff and the BO2 adapter/coupling with concentric tubing joint can also accommodate a subsurface safety valve.Control-line ports may be either threaded with seal sleeves or continuous, depending upon customer requirements.
WHEN ORDERING A. FMC Energy Systems Model B. Bottom Connection 1. Flanged, studded or clamp hub 2. Size 3. Working pressure
Tu b i n g H a n g e r s , s p e c i f y t h e f o l l o w i n g :
C. Top Connection 1. Flanged, studded, male thread or female thread 2. Size 3. Working pressure D. Single or Dual Completion E. Tubing Size(s)
53
F. Tubing Thread(s) G. With/Without SCSSV Control Line Port(s) H. Service: Regular or H2S I. Material Class Available to meet all appropriate API-6A requirements.
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SYSTEMS SOLUTIONS
We
[
L isten
A broad range of technology, more than 75 years of experience designing and delivering wellhead systems, a worldwide presence and the ability to listen. In this section, we present a variety of actual solutions in which listening to our customers, understanding their needs and responding with custom-engineered systems resulted in solutions to some of the industry’s challenges, offshore and inland.
FMC
Surface
technology meet
and
Wellhead
experience
your
needs
has to
]
the
confidently
worldwide.
W e a r e c o n f i d e n t that we can understand your challenge worldwide. Our multinational engineering teams and service technicians are deployed and supported globally, and most of them have built their experience locally before they came to our engineering hubs. Probably your FMC Surface Wellhead engineers will speak your language and be graduates of engineering schools in your region. At FMC Surface Wellhead you can find the balance between the most advanced technology for offshore projects, and years of worldwide field experience executing infield drilling programs under time and budget constraints. That makes us feel confident that we can work with our customers and together find the most appropriate specification for their needs.
54
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Systems Solutions
{ } “We are thoroughly satisfied with
the reliable solutions and support
provided by FMC Energy Systems.
They’ve proven themselves a proac-
tive wellhead supplier, committed to
performance and safety in helping us bring our North Sea field onsteam – on time and under budget.” MAJOR OIL COMPANY
55
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SYSTEMS SOLUTIONS
ESP
System
Kome (Chad) A major oil company faced a substantial logistical challenge when it developed an oilfield in a region of Africa with no established oilfield infrastructure and remote from existing shipping channels. This operator wanted the most reliable enhancedrecovery surface wellhead technology on the market for the venture and looked to FMC Energy Systems to provide it. Our company has years of experience throughout Africa and knew the most reliable choice of technology the customer would require in Chad. We recommended a field-proven ESP system, including our industry-standard Model 120 gate valves, HNBR FMC-molded S & FS elastomer seals, and FMC C22 casing head, another industry standard. Each of these components has delivered at least 15 years’ outstanding field performance. Features and Benefits ◆ Vertical producer well ◆ Industry-standard FMC C-22 casing head (40 years of field experience) ◆ FMC Model 120 gate valves, 5,000/3,000 psi, Trim AA (20 years’ field experience) ◆ FMC S and FS HNBR interference elastomer seals (15 years’ field experience) ◆ FMC spool tubing type electro-sub and FMC ESP hanger and adapter solutions (30+ years’ field experience) ◆ Allow rapid deployment, suspension and retrieval using standard BOPs, completion procedures and hoisting equipment ◆ Meet all international electric codes and certifications required ◆ Certified to API6A, Appendix F, PR-2 plus additional cycle testing
FH
System
Alberta (Canada) There are moments when the challenge is not the environment, the pressure or the reliability. Shallow, marginal low-pressure well production dictates a very tight budget. The oil company then needs to maximize its use of customer property and to utilize the adequate technology to match its application. There is not extra cash for any luxury beyond the basic requirements. At FMC Surface Wellhead we listened to market situations and decided to develop our FH line with tapered bowl and exclusive elastomer seal design to stay “on budget.” Features and Benefits ◆ Tapered configuration matching the market needs ◆ Elastomeric seal ◆ Low pressure ◆ Material Trim AA ◆ Pressures up to 2,000 psi o o ◆ Temperature –50 F to 250 F
56
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Time Optimization (DTO) System
Rocky Mountains (United States) Our customer’s infield drilling program needed to minimize his rig time for multiple shallow wells (with surface casing pressures less than 5,000 psi) and to improve safety. FMC Surface Wellhead’s solution was the DTO ® wellhead, which delivers significant time savings by eliminating a number of steps in the traditional drilling process and reducing time required for other steps. The ideal situation for using the DTO would be a single rig that’s drilling multiple consecutive wells by using a common casing program. Each rig is outfitted with a DTO diverter connector fabricated into a diverter riser. The assembly stays with the rig for the drilling project, and it is used on each well. A DTO drilling spool connector is assembled into the rig BOP and is moved with the rig from well to well. Features and Benefits ◆ Eliminates steps in the drilling process. ◆ Offers time savings during nipple up/down of the BOP’s stack, landing casing hanger and installing the tubing head. ◆ Increases safety by eliminating the need for cutting torches and hammer wrenches. ◆ Locking ring design on drilling spool provides 360 degrees engagement to increase load capacity and reduce fatigue. ◆ Contingency systems for stuck pipe retains system benefits and time savings. ◆ Tests production casing seals prior to removal of BOP. ◆ Load capacity of surface casing hanger exceeds joint strength.
Fast
Drilling System
Ohanet (Algeria) The customer’s priorities were: reducing rig downtime, simplicity of wellhead installation and contingency procedures in place. These parameters and more were met by FMC Energy Systems. For more than 10 years, we’ve supplied this customer with our proprietary simple but rugged Unihead ® thru-bore solution. This system is designed to be installed as a single piece, which results in significant time savings during drilling by eliminating the need to nipple down and up BOP stacks. The casing is easy to access in the event pipe is stuck downhole, a feature that eliminates the need for complex casing cutters. The system is so simple that, in the event of logistics problems, it can easily be installed by a competent drilling crew. Features and Benefits ◆ 45º landing shoulders for all mandrel and tubing hangers ◆ Weight set J slot packoffs incorporating FMC S and FS elastomer seals, easy to lock in place using FMC ET lockdown screws ® ◆ Variety of 13 3/8˝ casing solutions from a thru conductor to FMC Sliploc ◆ Standard FMC TC-1A-EN tubing hangers for interchangeability – available in both 13˝ and 11˝” configurations for up to 10,000 psi applications ◆ Available in intermediate pressure rating 6,650 psi
57
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SYSTEMS SOLUTIONS
Fully
Featured System
Sarawak (Malaysia) This major European-based oil company planned to develop a high-flow-rate, corrosive field in Borneo. Not only does this company uphold the highest standards for safety of crew and environment, but it would be operating in a part of the globe that it had not previously explored. The company came to FMC Energy Systems for its reputation as a worldwide supplier familiar with the Far East and the challenges of working here, and known for the high reliability of our wellhead systems. Energy Systems sales engineers recommended technology appropriate to the highest standard required, a fully featured system with metal-to-metal seals and Speedloc® connections. We knew this would be the best cost-to-risk choice for the customer, who would not have to be concerned about the equipment performance over the life of the field. They also felt such a system would be easier and safer to install and safer over the life of the wells, and that it would save them rig time during installation. Features and Benefits Field-proven advanced technology ◆ Metal-to-metal seals ◆ Internal latches ◆ Minimum leak paths to the environment ◆
Fully
Featured System
North Sea (Norway) When a major oil company planned to develop a North Sea field, it estimated a 30year minimum lifetime for the field and projected future production with water cuts and gas penetration. The field would have 12 tie-back wells (predrilled wells from a semi prior to installing the platform) and was planned for production, gas-injection and water-injection wells. Moreover, the field is regulated by strict API6A and NORSOK standards. Needing reliable, flexible, cost-effective drilling and production solutions, this company came to FMC Energy Systems as we are the most experienced wellhead supplier in the North Sea for both surface and subsea applications. Our engineers proposed a fully featured surface system using thru-bore technology, including proven UWD 15 subsea technology, with the flexibility of switching from production to injection without changing trees. FMC Energy Systems’ Norway operations allow the customer to carry smaller inventories of equipment and parts, short lead time and ready access to engineers and technicians experienced in North Sea operations. Features and Benefits ◆ Thru-bore system with minimal installation time for risers and BOP. Installation time reduced by implementing field-proven subsea UWD 15 casing hangers and packoffs. ◆ Top-of-the-line materials and cladding assure equipment will last through the life of the well with minimum maintenance and lost production. ◆ Has metal-to-metal seals, UWD 15 technology. ◆ Switch from production to injection without changing out trees. ◆ By having the 18 3/4˝ casing landed in the starting head, the operator can easily change out the 13˝, 9˝ and 7˝ tubing and Unihead® when the well needs slot recovery, workover, etc. ◆ Wireshear actuator on master valve can shear 7/16th braided wire on the tree to save time and money rigging wireline equipment. 58
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Featured System
China Sea (China) This project in the China Sea’s Ya Cheng field, which supplies gas energy to Hong Kong, presented the challenges of critical conditions: high corrosive, high temperature, fire resistant, severe weather, large-bore production, high reliability and a long life cycle to reduce the need for workovers. Our state-ofthe-art “dry tree” system, the UWD-15, is an excellent example of our quest to design highly reliable wellheads for difficult environments and conditions and still contain costs. Developed out of our subsea wellhead technology, the UWD-15 is a 15,000 psi wellhead that combines advanced technology for high-pressure and hazardous-service environments. All seals are metal-tometal, with the UWD-15 packoff providing the basis for annular sealing. This packoff does not rely on the tubing hanger weight to energize and can be removed separately from the tubing hanger. It utilizes an SBMS seal at the tubing hanger neck as standard. The seat is recessed to help ensure that the seal contact surface is not damaged when the packoff is installed. The design includes a fire-safe envelope for the upper master valve to the annulus A. Features and Benefits ◆ The 15,000 psi wp UWD-15 Wellhead System minimizes leak path to the environment. ◆ Has a metal-to-metal seal, SBMS technology. ◆ Includes internal latch. ◆ Has major connections with Speedloc ®. ◆ Offers field-proven advanced technology. ◆ Standard subsea tooling facilitates availability and learning processes.
H igh-Pressure
Gas System
Oman Desert (Oman) In the desert of Oman, conditions to produce gas are severe to critical. The equipment needs to have temperature class X and to resist high-corrosive fluids up to 13,000 psi pressure. The operator has one of the highest safety standards in the industry, and he was looking for a local manufacturer. Our multicultural team successfully implemented our equipment while managing the project, and provided support during execution. FMC Surface Wellhead elastomeric seal achieved exactly the customer’s requirement. Features and Benefits ◆ Has single Unihead system with two-step bowls. ◆ Major connections are comprised of FMC Speedloc-II segmented clamps. ◆ Packoff and tubing hanger assembly utilizes elastomeric sealing technology and internal latch mechanism.
59
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SYSTEMS SOLUTIONS
Ho r i z o n t a l
System
Gulf of Campeche (Mexico) Injecting 1.2 million cubic feet of nitrogen per day into a formation through a 9˝ bore is a major challenge to face with traditional solutions. The limited available height and weight on the platform plus the handling of a 9˝ Christmas tree during installation and workover ruled out a conventional production wellhead solution. Our engineers who have platform working experience understood better than other suppliers the operational challenge, and proposed the first horizontal wellhead tree system of its size in the Gulf of Mexico. Features and Benefits ◆ Full 9˝ bore system. ◆ Allows workover without removing Christmas tree. ◆ It has hydraulic or pneumatic valves. ◆ Wire Mesh FMC Surface Wellhead seal technology. ◆ Allows drilling through the tubing hanger. ◆ Maximizes platform’s available surface.
Side-By-Side
(SXS)® System
Java Sea (Indonesia) Fragmented reservoirs requiring multiple interventions are a major challenge due to the reduced space on platforms, especially when, as in this example, you need to complete (or abandon) wells and perform interventions without disturbing adjacent wells. For such challenges, FMC Surface Wellhead has developed a Side-By-Side (SXS) Wellhead System for optimization of space on new platforms or workovers on existing platforms. The SXS also accommodates configurations involving a combination of single and dual completions inside a single conductor. Features and Benefits ◆ Allows installing either a 2-in-1 or 3-in-1 well configuration inside a single conductor, sized from 26˝ OD onwards to suit requirements. ◆ Eliminates the need for additional conductor pipe. This creates up-front savings and reduces abandonment costs. ◆ Allows the use of standard drill-bit sizes. ◆ Independent Tubing Heads (Unihead ®) allow greatest flexibility in choosing wells to complete or abandon and to perform independent intervention, entry and re-entry without disturbing adjacent wells or flow lines. The wellheads are installed with full BOP protection. This system promotes time saving through batch drilling and drilling with reduced rig move time. ◆ Maximize platform size and the use of well slots on the platform. For existing wells, the SXS wellhead maximizes the use of existing spare well slots.
60
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T L P / S PA R
Page 8
System
Gulf of Mexico (USA) By far the most experienced suppliers of TLP/SPAR systems in the Gulf of Mexico, we also installed the deepest and most fire-resistant SPAR in the Gulf. As certain platforms are designed to move with water action, every element connected to the sea floor becomes an integral part of a dynamic system and requires specialized wellhead solutions like our TLP/SPAR systems. From the initial stages of your project, we can help you decide to go with a “wet” or a “dry” tree. Example: If you’re facing a fragmented reservoir offshore and must execute multiple interventions, economics indicate a surface tree. FMC Surface Wellhead installed the first TLP/SPAR system in the Gulf of Mexico during the 1980s and has been the leader in this technology since, installing more systems worldwide than our competitors combined. Features and Benefits Special slip-lock assembly securely attaches wellhead to riser. ◆ Straight-bore metal seal (SBMS) provides a more secure seal against heavy sideloads that can be generated by wave activity. ◆ More compact profile reduces vertical space requirement. ◆ New tubing head design provides full metal-to-metal seal. ◆ Special plug and lubricator adapter provides easy vertical access to the gas-lift string. ◆ SCSSV and inhibitor lines exit through the upper wellhead connection. ◆
CM-1
Shallow-Water System
Black Sea (Ukraine) The CM-1 is a subsea tree utilized to complete subsea wells on mudline suspension systems. It is expressly designed for marginal field completions with small and fragmented reservoirs in jack-up depths. The CM-1 Tree’s modular design integrates the latest field-proven technology into a simple design that minimizes installation time and reduces total installation costs. The versatility of the system allows the operator to tie back to most mudline systems and casing programs. FMC Surface Wellhead first introduced the CM-1 Tree in 1975. Features and Benefits ◆ Adapts to any major wellhead manufacturer mudline equipment. ◆ Taps small reservoir and ties back to existing platform. ◆ Diver-installed, modular 3-inch, 10,000 psi working pressure production tree minimizes dives and running trips. ◆ Has 2-inch side annulus access. ◆ Eccentric mandrel-type monobore tubing hanger has four downhole penetrations (configured to operator specifications). ◆ Has direct hydraulic control system. ◆ Has 4-inch, 10,000 psi swivel-flange flowline connection. ◆ Is API Material class FF. ◆ Offers optional downhole or tree chemical-injection methods. ◆ Offers optional pressure and temperature transducers.
61
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Page 1
Valves
V
Series 100 alves FMC Surface Wellhead’s gate valves are the industry’s standards for strength, reliability and durability. Our valves are designed and tested for a minimum 20-year life – everything you need in a valve.
[
[
A wellhead is as good as its valves, and FMC Surface Wellhead’s valves are as good as it gets.
S e r i e s 1 0 0 G a t e Va l v e s FMC Surface Wellhead’s Series 100 Gate Valves have successfully met customer demands for performance, endurance and ease of maintenance since their introduction in 1984. Available in working pressures from 2,000 to 20,000 psi, these metal-seal gate valves provide bubble-tight operation throughout their rated pressure and temperature ranges. Sizes, configurations and materials are available for virtually any application. Model 100 Series Valves by far exceed the requirements of API 6A. Model 120, Model 125, Model 130, Model 135, Model 160 and Model VLT have been qualified in excess of Appendix F for material class AA to HH and temperature rating –75 to 400oF. An additional 300 endurance cycles are applied to simulate 20 years of life expectancy. Series 100 gate valves come in trims for a complete range of water, oil and gas services – including corrosive, high-temperature, subsea, arctic, sand and steam.
Belleville spring
Metal-to-Metal seal design FMC Surface Wellhead’s Series 100 gate valves use a precision-machined floating slab gate and seat design that provides a fully energized metal-to-metal seal between the gate and seat surfaces at all times. A Belleville spring behind each seat keeps the seat in contact with the gate to ensure effective sealing at very low pressures. These fully symmetrical valves effectively seal against flow in either direction. Even though the seats “float” in their respective pockets, the downstream seat still creates a metal-to-metal seal against the body when the valve is closed. The back face of each seat has FMC Surface Wellhead’s exclusive double-bump profile (right figure). As the valve closes, line pressure forces the gate against the downstream seat, which in turn is driven against the back of the pocket, where the double bumps form a gas-tight, metal-to-metal seal.
Teflon V-ring Teflon U-seal
Double bump
62
FMC Surface Wellhead’s patented UV stem packing is unaffected by H2S, CO2, amines and chlorides. It seals bubble-tight at pressures exeeding 20,000 psi at –75oF to 400oF temperature range, eliminating explosive decompression.
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Va l v e s Actuators Seals
Model 100 Series valves offer the following features:
API 6A PR AppF Qualified Fully Field Serviceable ◆ Floating Slab Gate ◆ Selective Stem Back Seating ◆ Bi-directional Operation ◆ Full Metal Sealing ◆ ◆
Patented nonelastomeric UV stem packing
Nonrising stem
Replaceable lift nut
Belleville springs
Close-fitting gate guide
Forged body and bonnet
Model 100 Series Valve
Easy Maintenance and Repair All components of FMC Surface Wellhead’s Series 100 valves are designed to last the life of the valve with a minimum of maintenance. Lubrication of the stem bearings and occasional greasing of the valve are the only routine maintenance required. Our R&D group developed a grease study with worldwide scope to improve gate valve performance in Surface and Subsea business applications. As a result of the study, we only use approved greases. FMC Surface Wellhead-approved greases have low torque and excellent washout resistance, and are hydrocarbon, H2S, and CO2 resistant. Reference grease guideline G70310. 63
Series 100
Packing nut seal
Stem bearing
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Valves
Model 101 FMC Surface Wellhead’s Model 101 gate valve exceeds API 6A PR1 and PR2 modified performance test. It is the newest offering in our Series 100 Gate Valve. This compact, safer-to-handle and rugged valve is ideal for a wide range of lower-pressure applications. Combined with the industry-proven Model 120 and Model 130 premium gate valves, FMC Surface Wellhead can support your every gate valve requirement. The Model 101 utilizes innovative design and advance material technology to deliver a highly reliable valve to match your low-pressure/low-demanding applications. The Model 101 is available in 2,000, 3,000 and 5,000 psi working pressures. Sizes and end connections meet a complete range of general and sour service oilfield applications. F e a t u re s a n d B e n e f i t s ◆ ◆ ◆ ◆ ◆ ◆ ◆ ◆ ◆ ◆ ◆ ◆
Has bi-directional flow. Nitrited and lapped gate and seat provide extended life expectancy. Soft seat provides extremely low-pressure seal ability (20 psi). Nonelastomer stem packing is unaffected by most oilfield chemicals. Has a nonrising stem. Casting and bolting technology reduces weight and maintains pressure capacity of two times working pressure. Has low torque requirements for easier opening and closing. Has tested beyond API 6A PR1 requirements. Floating seats allow quick and easy field repair. Stem packing seals without periodic energizing. Reliability of seats reduces leaks. Has a quick-disconnect hand wheel.
D
B
C
A
M O D E L
Nominal Size
Working
A
A
(Inches)
Pressure
(THD)
(FLG)
2 1/16
2 9/16
3 1/8
A
1 0 1
Dimensions
Flanged
Threaded
(Inches)
End Weight
End Weight
Turns to
D
(Lbs.)
(Lbs.)
Open/Close
B
C
Number of
2000
9.00
N/A
10.68
4.61
14.44
7.00
N/A
59
22 1/2
3000
9.00
14.62
10.68
4.61
14.44
7.00
95
59
22 1/2
5000
9.00
14.62
10.68
4.61
14.44
7.00
95
59
22 1/2
2000
10.62
N/A
12.84
6.98
16.53
7.00
N/A
145
23 4/5
3000
10.62
16.62
12.84
6.98
16.53
7.00
188
145
23 4/5
5000
10.62
16.62
12.84
6.98
16.53
7.00
188
145
23 4/5
3000
N/A
17.12
12.84
6.98
16.53
7.00
188
N/A
35 3/5
5000
N/A
18.62
12.84
6.98
16.53
7.00
216
N/A
35 3/5
Sizes
End Connections
Wo r k i n g P r e s s u r e s
Tr i m
2 1/6˝ 2 9/16˝ 3 1/8˝
FE, LP, EUE FE, EUE FE
2,000 psi 3,000 psi 5,000 psi 2,000 psi 3,000 psi 5,000 psi 2,000 psi 3,000 psi 5,000 psi
AA,BB,DD AA,BB,DD AA,BB,DD
64
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M ODEL
1 0 1 G a t e Va l v e
The improved version of an FMC industry Low torque
standard, our Model 101 Gate Valve is the newest solution for low-pressure applications. Backed by a long history of performance, the newest version of the Model 101 offers greater economy and value for the budgets of mature fields. The Model 101 joins our premium gate valve line, surpassing the competition in our
Nonelastomeric stem packing
See the results below.
Metal-to-metal and soft-seat sealing (20 psi low-pressure sealability)
Best-in-Class Results P E R F O R M A N C E
C O M PA R I S O N
T E S T I N G
FMC Energy Systems
Competitor
Competitor
Competitor
Gate Valve Model 101
Slab Gate Valve
Wedge Gate Valve #1
Wedge Gate Valve #2
API 6A PR1 Test Passed
Passed
Passed
Failed, seat leak on last test
Torque to Open
18 ft.- lbs.
10 ft.- lbs.
35 ft.- lbs.
50 ft.- lbs.
Running Torque
8 ft.- lbs.
5 ft.- lbs.
10 ft.- lbs.
15 ft.- lbs.
160 @ ambient temperature
160 @ ambient temperature
160 @ ambient temperature
Test not done; valve failed PR1 Test
5 @ 150oF
5 @ 150oF
5 @ 150oF
API 6A PR2 Test Modified Cycles Completed
o
o
5 @ 180 F
5 @ 180 F
o
o
5 @ 180oF
20 @ 250 F
20 @ 250 F
20 @ 250oF
Passed
Passed
Failed, stem packing leak
1 Hr Seat Test @ 250 F
Passed
Passed
Failed, stem packing leak
1 Hr Seat Test @ -20oF
Passed
Failed
Test not done
1 Hr Shell Test @ 250oF o
1 Hr Seat Test @ 0oF
Passed
Failed
Test not done
Results of the modified PR2 Test
Passed
Failed
Failed, stem packing leak
Condition of Critical Components after Testing Gate
Discoloration from gate movement across the seats
Slighty scored in gate faces
Slightly scored in gate faces
Deep scores in gate face
Seats
PTFE standoff good, no extrusion observed
Explosive decompression in seat seals
PTFE inserts extruded and metal face scored
Metal face of seat scored
Stem
Good
Minimal thread wear
Minimal thread wear
Minimal thread wear
Packing
Still Intact
Still Intact
Severely damaged
Some extrusion
65
Model 101
tests, qualifying it as the best in its class.
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Valves
Model 120 FMC Surface Wellhead’s Model 120 gate valve exceeds API 6A PR2 Appendix F performance test and FMC 300 endurance test. It is designed for medium-pressure oil and gas applications. The Model 120’s features have provided customers with many years of reliable services and the best sealing performance in the industry. It is a forged valve designed for 2,000, 3,000, and 5,000 psi working pressure. Model 120
D
F e a t u re s a n d B e n e f i t s ◆ ◆ ◆
◆ ◆ ◆ ◆ ◆ ◆ ◆ ◆ ◆ ◆
Heavy-duty, tapered roller thrust bearings Four redundancy seals on seat Metal-to-metal seals o Seat-to-gate o Stem backseat o Antiblowout packing nut o Seat-to-body o Bonnet gasket Reduced leak paths Quick-disconnect hand wheel Nonrising one-piece stem Nonelastomeric patented UV stem packing, bubble tight at –75 oF to 650oF Stem safety shear pin Stem featuring weak point above stem packing to allow contingency break off (pressure isolated) Advance hard-facing and coating technology on gates and seats to ensure reliability and wear resistance over 20 years of life Replaceable gate-lifting nut Stainless-steel gate guides Floating gate
M O D E L
Nominal Size (Inches) 2 1/16
2 9/16
3 1/8
4 1/16
5 1/8
6 3/8
Working
C
A
1 2 0
Dimensions (Inches)
Pressure
A
B
C
D
2000 3000 5000 2000 3000 5000 2000 3000 5000 2000 3000 5000 2000 3000 5000 2000 3000 5000
11.620 14.620 14.620 13.120 16.620 16.620 14.120 17.120 18.620 17.120 20.120 21.620 22.120 24.120 28.620 22.120 24.120 29.000
20.640 20.640 20.640 22.457 22.457 22.457 25.591 25.591 25.591 28.851 28.851 28.851 34.067 34.067 34.067 45.350 45.350 45.350
5.157 5.157 5.157 6.140 6.140 6.140 7.234 7.234 7.234 8.953 8.953 8.953 10.430 10.430 10.430 14.010 14.010 14.010
10.000 13.000 13.000 10.000 13.000 13.000 10.000 15.000 15.000 15.000 18.000 18.000 20.000 20.000 26.000 – – 27.000
66
B
Flanged End Weight
Threaded End Weight
Number of Turns to
(Lbs.)
(Lbs.)
Open/Close
165 165 165 275 275 275 330 330 330 590 590 590 880 880 880 1335 1335 1335
150 150 150 260 260 260 315 315 315 – – – – – – – – –
12 12 12 15 15 15 18 18 18 23 23 23 28 28 28 38 38 38
1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/8 1/8 1/8 1/4 1/4 1/4
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Page 6
Patented UV stem packing
Model 120
Replaceable lift nut (Improves torque and galling resistance)
Dual seal to body metal seal
M O D E L
1 2 0
Material Class Designation
Body & Bonnet
AA
Forged Alloy Steel
BB
Forged Alloy Steel
CC
Forged Stainless Steel
DD
Forged Alloy Steel
EE
Forged Alloy Steel
FF
Forged Stainless Steel
HH
Forged Alloy Steel w/CRA
Gates & Seats
Alloy Steel
Stainless Steel
Stainless Steel
Alloy Steel
Stainless Steel
Stainless Steel
CRA
Stem
Alloy Steel
Stainless Steel
Stainless Steel
Alloy Steel
Stainless Steel
Stainless Steel
CRA
Stem Packing
Patented
Patented
Patented
Patented
Patented
Patented
Patented
UV Design
UV Design
UV Design
UV Design
UV Design
UV Design
UV Design
Stainless Steel
Stainless Steel
Stainless Steel
Stainless Steel
Stainless Steel
Stainless Steel
Bonnet Gasket Seal
Stainless Steel or CRA
M O D E L 1 2 5 The FMC Surface Wellhead Model 125 is an extension of the FMC Surface Wellhead Model 120 Series gate valves that offers a lower-cost option for working pressures in the 4,500 psi to 6,500 psi working pressure. The Model 125 has the same features and benefits as the Model 120 plus the following upgrades on: 1) seat and gate hard facing, 2) lift nut material and 3) stem material. The result is an API monogrammed 5K service valve with FMC certification for use up to 6,650 psi working pressure. The Model 125 is available in sizes from 2 1/6˝ to 6 5/8˝, in a temperature range from –75oF to +250oF, and qualified by for API 6A PR2 App F plus 300 endurance cycles.
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Valves
Model 130/150 FMC Surface Wellhead’s Model 130/150 gate valve exceeds API 6A PR2 Appendix F performance test and FMC Surface Wellhead 300 endurance test. It is designed for high-pressure oil and gas applications. The Model 130/150’s features have provided customers with many years of reliable services and the best sealing performance in the industry. It is a forged valve designed for 10,000 and 15,000 psi working pressure. F e a t u re s a n d B e n e f i t s ◆ ◆ ◆
◆ ◆ ◆ ◆ ◆ ◆ ◆ ◆ ◆ ◆
D
Heavy-duty, tapered roller thrust bearings Four redundancy seals on seat Metal-to-metal seals o Seat-to-gate o Stem backseat o Antiblowout packing nut o Seat-to-body o Bonnet gasket Reduced leak paths Quick-disconnect hand wheel Nonrising one-piece stem Nonelastomeric patented UV stem packing, bubble tight at –75oF to 650oF Stem safety shear pin Stem featuring weak point above stem packing to allow contingency break off (pressure isolated) Hard-facing technology on gates and seats to ensure reliability and wear resistance over 20 years of life Replaceable gate-lifting nut Stainless-steel gate guides Floating gate
B
C
A
M O D E L Nominal Model Size (Inches)
1 13/16
Working Pressure
130
10000
150
15000
130
10000
150
15000
130
10000
150
15000
130
10000
150
15000
4 1/16
130
10000
5 1/8
130
10000
6 3/8
130
10000
2 1/16
2 9/16
3 1/16
A
18.31 18.19 18.06 17.94 20.56 20.44 19.06 18.94 22.31 22.19 21.06 20.94 24.44 24.32 23.62 23.50 26.44 26.32 29.06 28.94 35.06 34.94
1 3 0 / 1 5 0
Dimensions (Inches) B C
D
Flanged End Weight (Lbs)
# Turns to Open/Close
22.574
5.439
16.000
175
11 3/8
24.633
6.075
16.000
450
12 3/8
23.169
5.950
16.000
205
12 3/4
26.255
6.687
17.000
340
26.364
6.977
16.000
300
15 1/2
29.643
7.901
19.000
600
13 5/8
28.941
8.015
17.000
420
18 3/8
33.425
9.155
22.000
700
16
34.273
10.113
24.000
960
19 1/8
42.177
12.580
27.000
110
18
49.665
15.000
33.000
2099
68
1
22 1/8
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Patented UV stem packing
Replaceable lift nut (Improves torque and galling resistance)
Proprietary low-friction high-temperature facing
M O D E L
1 3 0 / 1 5 0
FMC Surface Wellhead Material Class Designation
AA
BB
CC
DD
EE
FF
HH
Body & Bonnet
Forged Alloy Steel
Forged Alloy Steel
Forged Stainless Steel
Forged Alloy Steel
Forged Alloy Steel
Forged Stainless Steel
Forged Alloy Steel w/CRA
Gates & Seats
Alloy Steel
Stainless Steel
Stainless Steel
Alloy Steel
Stainless Steel
Stainless Steel
CRA CRA
Stem
Alloy Steel
Stainless Steel
Stainless Steel
Alloy Steel
Stainless Steel
Stainless Steel
Stem Packing
Patented
Patented
Patented
Patented
Patented
Patented
Patented
UV Design
UV Design
UV Design
UV Design
UV Design
UV Design
UV Design
Stainless Steel
Stainless Steel
Stainless Steel
Stainless Steel
Stainless Steel
Stainless Steel
Bonnet Gasket Seal
Stainless Steel or CRA
M O D E L 1 3 5 The FMC Model 135 is an extension of the FMC Model 130 Series gate valves that offers a lowercost option for working pressures in the 9,000 psi to 12,000 psi working pressure range. The Model 135 has the same features and benefits as the Model 130 plus the following upgrades on: 1) seat and gate hard facing, 2) lift nut material, 3) stem material and 4) bolting. The result is an API monogrammed 10K service valve with FMC Surface Wellhead certification for use up to 12,500 psi working pressure. The Model 135 is available in sizes from 2 1/6˝ to 4 1/6˝, in a temperature range from –75oF to +350oF, and qualifies by API 6A PR2 App F plus 300 endurance cycles.
69
Model 130/150
Dual seal to body metal seal
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Valves
M odel 130/150 VLT FMC Surface Wellhead’s Model 130/150 VLT gate valve exceeds API 6A PR2 Appendix F performance test and FMC Surface Wellhead 300 endurance test. The “VLT” family was designed as an option to gear reducers to achieve low torque and ease operation. It is an extension of the FMC Surface Wellhead’s M120 and M130, with many of the same features plus reduced-torque technology. FMC Surface Wellhead’s technology has reduced the operating torque more than 95% for the designed applications. The VLT is selectively offered in the following sizes: 9˝ for 2,000 to 5,000 psi; 4 1/16˝ to 7 1/16˝ for 10,000 psi, and 3 1/16˝ to 7 1/16˝ for 15,000 psi. Temperature range is from –75oF to 400oF. Features and Benefits ◆ 95% reduction in operating torque o o ◆ Nonelastomeric patented UV stem packing, bubble tight @ –75 F to 650 F (bonnet and balanced stem housing) ◆ Metal-to-metal seals o Seat-to-gate o Bonnet gasket o Seat-to-body o Balance stem backseat ◆ Stem backseat ◆ Bi-directional sealing ◆
Replaceable gate-lifting nut
◆
Stem safety shear pin Quick-disconnect hand wheel Balanced stem with back seat Rising stem Sealed integral roller screw assembly threaded to bonnet Integral FMC patented roller screw mechanism and a balancing stem Manually operated with no gear reducers One-to-one ratio
◆ ◆ ◆ ◆ ◆ ◆ ◆
D
B
C
A
M O D E L Nominal Size (Inches)
Model
3 1/16 4 1/16 5 1/8 6 3/8
1 3 0 / 1 5 0
Working Pressure
A
Dimensions (Inches) B C
150
15000
22.000
52.500
130
10000
26.380
56.200
150
15000
29.000
62.800
V L T D
Flanged End Weight (Lbs.)
# Turns to Open/Close
17.790
23.560
973
20.20
19.550
24.000
955
24.20
20.439
27.000
1730
25.30
130
10000
29.000
69.700
23.280
27.000
1723
30.20
150
15000
35.000
75.900
25.775
27.000
3125
31.90
130
10000
35.000
79.700
27.025
27.000
70
37.20
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M ODEL
V LT
The FMC Model VLT is an extension of the Model 100 Series gate valves that offers 95% torque reduction. It features an integral FMC Energy Systems patented roller screw mechanism and a balancing stem. The VLT family was designed for manual operation Extremely low torque
with no gear reducers, achieving a "one-to-
(95% torque reduction)
one" ratio. The Model VLT features include: multiple seat barriers, bubble - tight shutoff, over-torque prevention and a replaceable lift nut.
Integral sealed FMC Energy Systems patented roller screw 1-to-1 ratio turn (No gear reducers)
Rising stem
M o d e l 1 3 0 / 1 5 0 V LT
Balanced stem with metal back seat and patented UV stem packing
L O N G L I F E E X P E C TA N C Y A N D R E L I A B L E O P E R AT I O N Key features to ensure reliability for the life of the valve are: Metal-to-metal sealed bonnet assembly: Separate weather seals on the Series 100 valve bonnet assemblies isolate the stem, stem bearings, packing nut and other internal components from external environment. Heavy-duty stem bearings: Dual stem bearings support all axial loading on the stem. These low-friction, tapered roller bearings also help reduce operating torque. High-strength stem threads: Standard ACME threads offer high shear strength and high contact area for maximum endurance. A separate gate-lift nut contains the mating threads instead of the gate itself. This flexible design permits optimum stem/lift nut material combinations and allows the gate to float independently from the stem. In the unlikely event of thread damage, only the nut or stem needs to be replaced. Stem shear pin: The stem is protected against accidental twist-off by the stem shear-pin. The pin can be quickly replaced without disassembling the valve bonnet. Close-fitting gate guides: Stainless-steel gate guides stay within a few thousands of an inch of the gate, acting as mud skirts to minimize well fluids, sand and mud from entering the valve body as the gate opens and closes.
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Valves
M odel 160 FMC Surface Wellhead’s Model 160 gate valve exceeds API 6A PR2 Appendix F performance test plus FMC Surface Wellhead 300-cycle endurance test. Designed for high-pressure oil and gas applications. It is a forged valve designed for 20,000 psi working pressure. Features and Benefits ◆ Well balance designed and extremely low input torque ◆ Very reliable drive train components ◆ Seat Assembly designed with 5 redundancy seals ◆ UV stem packing reinforced with dual-spring and very rugged nonelastomeric designed for extreme conditions (HPHT) –50oF to +400oF @ 20,000 psi working pressure ◆ Stem features: 1. Nonrising stem 2. Hard-faced seal area to ensure bubble-tight seal @ HPHT condition and reusability 3. Efficiently designed thread to yield low-input torque at extreme conditions 4. Metal seal backseat ◆ Floating slab gate design with hard facing ◆ Heavy-duty, tapered roller-thrust bearing ◆ Robust bonnet-to-body gasket seal ◆ Selective backseating ◆ Metal-to-metal seal features: 1. Body-to-bonnet gasket 2. Seat to body – 3 redundant seals 3. Seat to gate 4. Stem backseat ◆ Stem safety shear pin ◆ Nongalling lift nut but replaceable if required ◆ Hard-facing technology on gates and seats to ensure reliability and wear resistance ◆ Easy to assemble – no special tooling required
D
B
C
A
The Model 160 was qualified to API 6A PR2 Appendix F at the following levels: 0oF to +350oF @ 20,000 psi full differential -20oF to +400oF @ 20,000 psi full differential -50oF to +350oF @ 20,000 psi full differential
M O D E L
1 6 0
Nominal
Working
Size
Pressure
A
B
C
D
E
F
(inches)
(psi)
( +/- .06)
(inches)
(inches)
(inches)
(inches)
(inches)
2 1/16
20,000
23.00
26.70
12.40
19.00
6.70
30.70
817
14
2 9/16
20,000
26.50
30.40
15.10
19.00
8.70
34.40
1204
17
20,000
30.50
34.50
16.94
22.00
9.94
38.50
1646
16
20,000
31.56
40.12
20.41
2180
21
3 1/16 4 1/16
(3)
(3)
11.63
Notes: (1) These weights are based on a body machined from block (nondie forge). (2) Min @ ambient temperature w/20K full differentia; Max @ 400oF w/20K full differential. (3) This valve will have Rotork Gear Operator with twin input shaft.
72
(3)
Weight (lbs.) (1)
Number of Turns to Open/Close
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Enhanced patented UV stem packing
Replaceable lift nut (Improves torque and galling resistance)
Enhanced wearresistent stem
Proprietary hardfacing to reduce wear and increase valve life
Triple-metal seat and body Model 160
M O D E L
1 6 0
FMC Surface Wellhead Material Class Designation
EE
FF
HH
Body & Bonnet
Forged Alloy Steel
Forged Stainless Steel
Forged Alloy Steel w/CRA
Gates & Seats
Stainless Steel
Stainless Steel
CRA
Stem
Stainless Steel
Stainless Steel
CRA
Stem Packing
Patented UV Design
Patented UV Design
Patented UV Design
Bonnet Gasket Seal
Stainless Steel
Stainless Steel
Stainless Steel or CRA
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A C T U AT O R P R O D U C T S
A ctuators
FMC Surface Wellhead offers its own actuator product line that includes the HP–PN Pneumatic Piston, the HP–HYW Hydraulic Wire Shear Actuator and the HP–HY Hydraulic Piston Actuator. This design has been proven worldwide in the field for more than 35 years.
D e s i g n F e a t u re s o f t h e F M C S u r f a c e We l l h e a d P n e u m a t i c a n d Hydraulic Actuators: ◆ ◆ ◆ ◆ ◆
The actuator is fail-safe/fail-close because it will close with the loss of control pressure, with or without pressure in the valve body. Heavy-duty coated spring package is designed to provide closing force at zero or low pressure. Actuators are designed with back-seat capability. Designed to accept our full range of accessories, i.e., stem protectors, fusible lockout caps, etc. Quick-disconnect design and spring box design reduces time required during maintenance operations.
HP– PN Pneumatic Piston Actuator mounted on a reverse-acting gate valve. The HP-PN Pneumatic Actuator is designed to be failsafe and fail-close. When installed as part of a safety system, it will automatically close with the loss of control pressure and will open automatically when the control pressure is restored.
74
[
[
Description: The Type HP-PN Pneumatic Piston Actuator is a ratio-piston-type actuator
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Functions ◆ ◆ ◆ ◆
◆ ◆
Actuators are used on secondary master valve and/or wing valve of a Christmas tree, flow lines, header valves, gathering lines and pipelines. As part of a surface safety system, the actuator will shut off flow from the well in the event of a catastrophic event. The HP-PN surface safety valve is a pneumatic-controlled actuator that is operated by an air or gas source. Pneumatic pressure acting on the piston holds the valve open. Loss of pneumatic pressure in the actuator’s cylinder allows the well or flowline pressure acting on the area of the lower stem to force the stem and gate closed. Pneumatic actuators can be used in both gas and oil wells. Care should be taken when using pneumatic actuators on high-pressure and/or large-bore applications. One of the opening characteristics of a pneumatic actuator is that once sufficient force is generated to break the differential, the valve will instantaneously go from closed to full open. This causes a slam-open effect that can cause damage to gates and seats. This can potentially damage the actuator. The following are some methods to reduce this potential problem: o Reduce the differential pressure across the valve. o Reduce the volume of air in the cylinder. o Dampener mechanism. o Use of a hydraulic actuator is considered the best option.
Benefits ◆ ◆ ◆ ◆ ◆ ◆ ◆ ◆
Loss of control pressure above the piston will cause the actuator to close the valve. In the event of a fire, the metal-to-metal seal between bonnet and lower stem acts as a secondary seal if the stem packing is damaged. Has a back-seat test port and packing leak detection port. A relief valve on the cylinder prevents overpressurization. Large piston area permits use of low-pressure air or gas control systems. Has a rising stem for visual indication. Pneumatic cylinder and piston are electrolysis nickel plated for corrosion resistance, reducing repair cost. Upper stem packing is easily removed. P N E U M A T I C
A C T U A T O R S
Size
Working Pressure
(inches)
(psi / Bar)
Valve
(inches / mm)
Valve Bore
Max Cylinder Pressure
2 1/16
5,000 / 344.7
FMC
2.06 /52.32
HP-PN 24
2 1/16
10,000 / 689.5
FMC
2.06 /52.32
HP-PN 29
250 / 17.24
2 9/16
5,000 / 344.7
FMC
2.56 / 65.02
HP-PN 24
250 / 17.24
2 9/16
10,000 / 689.5
FMC
2.56 / 65.02
HP-PN 33
250 / 17.24
3 1/8
5,000 / 344.7
FMC
3.12 / 79.25
HP-PN 29
250 / 17.24
3 1/16
10,000 / 689.5
FMC
3.06 / 79.99
HP PN 46
250 / 17.24
4 1/16
5,000 / 344.7
FMC
4.06 / 103.1
HP-PN 38
250 / 17.24
4 1/16
6,500 / 448.11
FMC
4.06 / 103.1
HP-PN 38
250 / 17.24
Type
(psi / Bar) 250 / 17.24
10,000 / 689.5
FMC
4.06 / 103.1
HP-PN 52
200 / 13.79
5 1/8
5,000 / 344.7
FMC
5.12 / 130.00
HP-PN 48
200 / 13.79
5 1/8
6,500 / 448.11
FMC
5.12 / 130.00
HP-PN 54
200 / 13.79
6 3/8
5,000 / 344.7
FMC
6.38 / 162.1
HP-PN 52
200 / 13.79
7 1/16
3,000 / 206.82
FMC
6.62 / 168.1
HP-PN 52
200 / 13.79
7 1/16
5,000 / 344.7
FMC
6.62 / 168.1
HP-PN 52
200 / 13.79
Identification The HP-PN Pneumatic Piston Actuator assembly includes the bonnet and the actuator assembly. The HP-PN actuator will be sized to open the valve against full differential with the available control pressure. The designation for the FMC Surface Wellhead pneumatic piston actuator is four alpha characters followed by two numeric characters. For example, the designator for a pneumatic piston actuator is HP-PN38. The HP is the product identifier; the PN references pneumatic piston, and the 38 refers to the piston size. A given piston size can be used on a number of valve sizes.
75
A c t u a t o r P ro d u c t s
4 1/16
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HP– HY Hydraulic Piston Actuator reverse-acting gate valve. The HP-HY Hydraulic Actuator is designed to be fail-safe and failclose. When installed as part of a safety system, it will automatically close with the loss of control pressure and will open automatically when the control pressure is restored.
Functions ◆ ◆ ◆ ◆
◆
The actuators are used on secondary master valve and/or wing valve of Christmas tree, flow lines, header valves, gathering lines and pipelines. As part of a surface safety system, the actuator will shut off flow from the well in the event of a catastrophic event. The HP-HY surface safety valve is a hydraulically controlled actuator that is operated by a closed hydraulic system completely independent of well fluids and pressure. Hydraulic pressure acting on the piston holds the valve open. Loss of hydraulic pressure in the actuator cylinder allows the well or flowline pressure acting on the area of the lower stems to force the stem and gate closed. Recommended for use in high-pressure and/or large-bore applications.
76
[
[
Description: The Type HP-HY Hydraulic Actuator is a ratio-piston-type actuator mounted on a
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F e a t u re s ◆ ◆ ◆
Control line port can be rotated 360°. Hydraulic section is resistant to corrosion. Has a quick-disconnect clamp.
Benefits ◆ ◆ ◆ ◆ ◆ ◆ ◆
In the event of a fire, the metal-to-metal seal between bonnet and lower stem acts as a secondary seal if the stem packing is damaged. Has a back-seat test port and packing leak detection port. Oil port can be rotated 360 degrees for easy alignment of power-source control line. Has a lifting eye to facilitate removing the actuator when mounted horizontally. Two bonnet types are available to cover a wide range of applications. The Type A bonnet is the extended version, and the Type B bonnet is the flush-mounted version. Nipoloy process (electrolysis nickel) is used on hydraulic cylinder for corrosion resistance. Hydraulic piston is hard chromed for corrosion resistance.
H Y D R A U L I C
A C T U A T O R S
Working
Cylinder Operating
Size
Pressure
Gate
Valve Bore
(inches)
(psi / Bar)
Valve
(inches / mm)
2 1/16
5,000 / 344.7
FMC
2 1/16
10,000 / 689.4
FMC
2 9/16
5,000 / 344.7
2 9/16
10,000 / 689.4
3 1/8
Max Cylinder
Pressure
Pressure
Type HP-HY
(psi / Bar)
(psi / Bar)
2.06 / 52.32
HP-HY 60
3,000 / 206.8
5,000 / 344.7
2.06 / 52.32
HP-HY 80
3,000 / 206.8
5,000 / 344.7
FMC
2.56 / 65.02
HP-HY 70
3,000 / 206.8
5,000 / 344.7
FMC
2.56 / 65.02
HP-HY 90
3,000 / 206.8
5,000 / 344.7
5,000 / 344.7
FMC
3.12 / 79.25
HP-HY 75
3,000 / 206.8
5,000 / 344.7
3 1/16
10,000 / 689.4
FMC
3.06 / 79.99
HP-HY 95
3,000 / 206.8
5,000 / 344.7
4 1/16
5,000 / 344.7
FMC
4.06 / 103.1
HP-HY 90
3,000 / 206.8
5,000 / 344.7
4 1/16
6,650 / 458.45
FMC
4.06 / 103.1
HP-HY110
3,000 / 206.8
4,500 / 310.3
4 1/16
10,000 / 689.4
FMC
4.06 / 103.1
HP-HY120
3,000 / 206.8
5,000 / 344.7
5 1/8
5,000 / 344.7
FMC
5.12 / 130.00
HP-HY 120
3,000 / 206.8
4,500 / 310.3
5 1/8
10,000 / 689.4
FMC
5.12 / 130.00
HP-HY 155
3,000 / 206.8
4,500 / 310.3
6 3/8
5,000 / 344.7
FMC
6.38 / 162.1
HP-HY 155
3,000 / 206.8
4,500 / 310.3
6 3/8
10,000 / 689.4
FMC
6.38 / 162.1
HY 175
3,000 / 206.8
5,000 / 344.7
Identification The HP-HY Hydraulic Piston Actuator assembly includes the bonnet and the actuator assembly. The HP-HY actuator will be sized to open the valve against full differential with the available control pressure. The designation for the FMC Surface Wellhead Hydraulic Actuator is four alpha characters followed by two numeric characters. For example, the designator for a Hydraulic Actuator is HP-HY90. The HP is the product identifier, the HY references hydraulic piston, and the 90 refers to the piston size. A given piston size can be used on a number of valve sizes.
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HP– HYW Hydraulic Wire Shear Actuator
Functions ◆ ◆ ◆ ◆
The actuators are used on the secondary master valve. They are the primary surface safety device during a wireline operation. As part of a surface safety system, the actuator will shear the wireline and seal off the flow from the well in the event of a catastrophic event. The HP-HYW surface safety valve is a hydraulically controlled actuator that is operated by a closed hydraulic system completely independent of well fluids and pressure. Hydraulic pressure acting on the piston holds the valve open. Loss of hydraulic pressure in the actuators cylinder allows the well or flowline pressure acting on the area of the lower stems to force the stem and gate closed. The spring package is sized to cut a specific size of wireline.
F e a t u re s ◆ ◆ ◆ ◆
Coiled spring design provides cutting force. Control line port can be rotated 360°. Hydraulic section is resistant to corrosion. Has a quick-disconnect clamp.
78
[
[
Description: The Type HP-HYW Hydraulic Actuator is a ratio-piston-type actuator mounted on a reverse-acting gate valve. The HP-HYW Hydraulic Wire Shear Actuator is designed to be failsafe and fail-close. The coiled multi-spring assembly provides the added shear force. When installed as part of a safety system, it will automatically close with the loss of control pressure and will open automatically when the control pressure is restored. The wire shear actuator becomes the primary surface safety device during wireline operations. Should an emergency take place while the wireline tool string is in the well, the wire shear actuator is designed to shear the wire and seal off the flow of the well.
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Page 18
Benefits ◆ ◆ ◆ ◆
◆ ◆ ◆ ◆ ◆
In the event of a fire, the metal-to-metal seal between bonnet and lower stem acts as a secondary seal if the stem packing is damaged. Has a back-seat test port and packing leak detection port. Spring packages are designed to fit customer application. FMC Surface Wellhead has provided spring packages to cut various-sized wires. We provide a North Sea operator a wire shear spring package to cut 7/16˝ braided line (shear force required was 22,400 lbs.). Oil port can be rotated 360 degrees for easy alignment of power-source control line. Has a lifting eye to facilitate removing the actuator when mounted horizontally. Two bonnet types are available to cover a wide range of applications. The Type A bonnet is the extended version, and the Type B bonnet is the flush-mounted version. Nipoloy process (electrolysis nickel) is used on hydraulic cylinder for corrosion resistance. Hydraulic piston is hard chromed for corrosion resistance. H Y D R A U L I C
W I R E
Working
S H E A R
A C T U A T O R S
Type
Cylinder Operating
Size,
Pressure
Gate
Valve Bore
OFS/HY-
Pressure
Pressure
inches
(psi / Bar)
Valve
(inches / mm)
XX W
(psi / Bar)
(psi / Bar)
2 1/16
10,000 / 689.5
FMC
2.06 / 52.32
90 W
3,000 / 206.82
4,500 / 310.23
3 1/8
5,000 / 344.7
FMC
3.12 / 79.25
90 W
3,000 / 206.82
5,000 / 344.7
3 1/16
10,000 / 689.5
FMC
3.06 / 79.99
100 W
3,000 / 206.82
4,500 / 310.23
4 1/16
5,000 / 344.7
FMC
4.12 / 104.64
100 W
3,000 / 206.82
5,000 / 344.7
4 1/16
6,500 / 448.11
FMC
4.06 / 103.1
110 W
3,000 / 206.82
4,500 / 310.23
10,000 / 689.5
FMC
4.06 / 103.1
140 W
3,500 / 241.29
5,500 / 379.17
5 1/8
5,000 / 344.7
FMC
5.12 / 130.00
140 W
3,000 / 206.82
5,000 / 344.7
5 1/8
10,000 / 689.5
FMC
5.12 / 130.00
160 W
3,000 / 206.82
5,000 / 344.7
6 3/8
5,000 / 344.7
FMC
6.38 / 162.1
160 W
3,000 / 206.82
4,500 / 310.23
4 1/16
Max Cylinder
Identification The HP-HYW Hydraulic Wire Shear Actuator assembly includes the bonnet and the actuator assembly. The HP-HYW actuator will be sized to open the valve against full differential with the available control pressure. The designation for the FMC Surface Wellhead Hydraulic Actuator is four alpha characters followed by two numeric characters. For example, the designator for a Hydraulic Wire Shear Actuator is HP-HYW90. The HP is the product identifier, the HY references hydraulic piston, W is for wire shear, and the 90 refers to the piston size. A given piston size can be used on a number of valve sizes. W H E N
O R D E R I N G
A C T U A T O R S ,
S p e c i f y
t h e
CUSTOMER DATA
GATE VALVE SPECIFICATIONS
ACTUATOR SPECIFICATIONS/REQUIREMENTS
EMERGENCY SHUTDOWN
F o l l o w i n g :
Bonnet Type: A (extended) or B (flush mount)
12)
Special Material and/or Processing Requirements
2)
Actuator Type: Pneumatic/Hydraulic
13)
System Requirements (If yes, add brief description.)
3)
Available Pneumatic/Hydraulic Pressure
4)
Maximum Shut-In Well Pressure
5)
Wire or Cable Size to Cut
14)
Solid Lockout Cap
6)
Closing Time for Actuator
15)
Fusible Lockout Cap Rated 95oC
7)
Regulatory Requirements
16)
Hydraulic or Manual Override
8)
Special API 6A Requirement
17)
Limit Switch: Go Type Intrinsically Safe
9)
Slam Test Required during SIT/FAT
18)
Limit Switch Housing: Stainless Steel or Aluminum
As in accordance with customer tender specification attached (If no, please state alternate.)
19)
Stem Protector: Slotted Metal, Transparent
20)
Repair Kit (consists of elastomers for bonnet and power section): FMC
Special Requirement/Certification/Witnessing Required
21)
Special Accessories Needed and/or additional comments related to inquiry
1)
10) 11)
ACTUATOR ACCESSORIES/REQUIREMENTS
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SEALS
T
Seal echnology Seals are critical for achieving reliable pressure integrity in wellhead equipment. FMC Energy Systems is proud of our sealing designs, and we would like to share our seal technology with you so you can take it into account next time you specify your equipment. Common oilfield elastomers are sufficiently reliable for low-pressure, normal-service oil and gas wells, and special elastomer compounds and designs are available for critical-service wells. However, all elastomer compounds lose some of their sealing effectiveness over time, with the rate of degradation dependent on environment. Sometimes a metal seal option can be a cost-effective way to increase service life and improve production efficiencies. FMC Energy Systems has the expertise to help you decide the best fit (elastomer or metal) for your application.
Elastomer
E lastomer
and
Metal
Seals
Seals
A number of the more conventional wellhead seals can no longer meet the new stringent design-acceptance criteria, such as the larger API casing and tubing OD tolerances now allowed by API Spec-5CT. For example, the conventional O-ring seal is very limited in its ability to bridge large extrusion gaps and remain intact without some kind of antiextrusion device. In addition, some seal designs cannot keep a bubble-tight seal over the wide temperature ranges and large pressure variations encountered. FMC Energy Systems’ response to these new API requirements addresses the limitations found in traditional interference and slab-packing applications with the following key design features: ◆ Seals meet API Spec. 6A, Appendix F, Performance Requirement Level Two (PR-2) pressure and temperature cycle testing. ◆ All seal designs utilize one of the FMC proprietary elastomeric compounds. These seal compounds are rated for all API material classes, including class HH (H2S/CO2 service), and are also amine resistant. ◆ Antiextrusion devices are incorporated into each type of seal design to compensate for thermal expansion/contraction of the seal element and for installation clearances. ◆ All seal elements and antiextrusion components are continuous. ◆ Antiextrusion devices are integrally molded into the seal element, making them easier to install and more durable. ◆ All seals are designed to provide proper squeeze, volume fill and stretch under all API/FMC tolerance conditions, i.e., the largest diametric gap possible and the worst-case misalignment of sealing surfaces.
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Seals
81
Seals
FMC Energy Systems’ patented “bump” seal design has addressed many issues traditionally associated with metal seals to become a technological breakthrough for wellhead equipment. FMC Energy Systems’ metal seals are rugged enough for the oilfield operation, have simple installation procedures, are easily tested after installation and are reusable in most applications. In most applications FMC Energy Systems metal seals are “self energizing” and do not rely on a wedging action, suspended weight or flange make-up force to affect a seal. The seal is “pressure assisted” and can work in any pressure. ◆ Meet API Spec. 6A, Appendix F, Performance Requirement Level Two (PR-2) pressure and temperature cycle testing. ◆ Are rated for all API material classes, including class HH (H2S/CO2 service) and are also amine resistant. ◆ Can be made from almost any high-strength steel or corrosion-resistant alloy, for use in extreme corrosive services. ◆ Work in all temperature ranges, from -75°F arctic service to 1200°F for fire-resistant applications. ◆ Are easy to install and test and can withstand standard oilfield handling. ◆ Do not deform (crush) metal, either on the seal or on the mating surfaces, so both are normally reusable, minimizing workover costs.
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SEALS
E lastomer Seals S-Seal The S-Seal is designed to provide reliable sealing between machined components. It is a versatile and reliable seal in cyclic high-pressure and -temperature applications, where conventional interference-type seals (O-rings, belt packing, dovetail, etc.) are typically inadequate. The S-Seal is an interference-type seal utilizing metal coil springs molded integrally into the exposed seal corners as antiextrusion devices. Another important feature of the FMC design is the use of a “continuous” coil spring, which eliminates weak points around the seal’s circumference. The S-Seal can be used in many applications where there is a controlled/machined gap between the sealing bore and shaft; for example, a mandrel hanger neck and tubing head adapter bore. There are both O.D. and I.D. applications of the S-Seal, with sizes available in nominal diameters up to 20˝. The S-Seal design can be rated up to 10,000 psi working pressure and a 0° to 250°F temperature range for all sizes. Special designs allow qualification to 15,000 psi working pressure and 300°F.
S-Seal
FS-Seal The FS-Seal has been designed to seal against rough casing where wide tolerances and varying surface finishes create difficult sealing conditions. It is utilized as a large cross-section interference seal to bridge large extrusion gaps associated with sealing on rough mill casing. The bump provides higher sealing contact stresses, while the curved recess on the back of the seal controls the amount of compression (squeeze) on the seal element by allowing it to deflect outward when sealing against a larger-than-normal outer-casing diameter or an out-of-round section of casing. The FS-Seal can be supplied integral to a casing-head bottom preparation as a 1-FS (one seal with no secondary) or 2-FS (two seals with one secondary) packoff. It can also be supplied as a separate 4-S packoff bushing, which incorporates a secondary S-Seal on the bushing OD and a secondary FS-Seal on the ID. The FS-Seal is available for 4 1/2˝ to 30˝ pipe sizes. The FS-Seal is rated to 10,000 psi working pressure and a 0° to 250°F temperature range for sizes up to 16˝, while the larger sizes are rated to 5,000 psi working pressure.
FS-Seal
Upper Junk Ring Nonextrusion RG OD Upper
Nonextrusion RG ID Upper
Nonextrusion RG ID Lower Lower Thread ACME Ring
Elastomeric Sealing Elements
PI Seal Assembly 82
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Tubing Head Adapter
S Seal Compression Ring Wire Mesh Compression Packing Lockdown Screw Tubing Hanger Tubing Head
Tubing
Elastomer Seal Diagram
Compression Packing with Wire Mesh This design is mechanically energized by lockdown screws after assembly and utilizes integrally molded wire mesh rings on top and bottom of the elastomeric element to increase extrusion resistance. Its design and elastomer compound enable excellent temperature and environmental resistance. It can be used up to 15,000 psi working pressure and a -50° to 250°F temperature range. The wire mesh is annealed 316 stainless-steel material for corrosion resistance.
Wire Mesh
Elastomeric Sealing Element
PI Seal The FMC PI Seal design is an extremely reliable high-pressure sealing mechanism. The PI assembly is comprised of an upper junk ring guide, the pressure-intensified (PI) seal assembly, and lower ACME threaded lock ring to hold the packoff in the bottom of the tubing head. The PI design addresses some rather complex problems associated with oilfield elastomer seal designs, including explosive decompression, extrusion at high pressures/temperatures, and seal shrinkage/poor response at low temperatures. The PI seal uses the casing annulus pressure to generate a higher pressure in the elastomer seal, which eliminates the diffusion of gas into the elastomer. This pressure intensification is generated by a movable “T” ring which creates an unbalanced pressure area across the elastomer seal. This design is coupled with FMC’s proprietary seal formulation, which also has improved gas permeation as well as excellent oilfield fluid resistance. The T-ring design also allows the elastomer to self-compensate for seal stress fluctuations caused by thermal cycling. The movement of the T-ring automatically controls excessive seal stresses caused by elastomer expansion. At very low temperatures, the phenomenon of seal stress relaxation caused by elastomer shrinkage is again automatically compensated for by annulus pressure applied to the unbalanced area T-ring. Seal failure due to extrusion is addressed by the use of automatic “ramping” antiextrusion rings made from thermoplastic material. The antiextrusion rings are located at all four corners of the seal. These rings compensate for the extrusion gaps caused by API casing tolerances and manufacturing head tolerances. The PI seal is rated to 15,000 psi working pressure and was developed for use as a lower casing or tubing spool packoff where long-term reliable sealing in hostile environments is required.
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M etal Seals SBMS Seals FMC Energy Systems’ straight-bore metal seal (SBMS) is energized by interference between the designated primary sealing surface and the metal seal’s contact area with that sealing surface. The SBMS is a nonintegral double-ended seal sleeve manufactured from high-strength, low-alloy steel or corrosion-resistant alloy. The seal can be installed separately and can be easily replaced. The seal design is based on an interference fit with pressure-intensified sealing. As the tubing head bonnet is nippled up, the seal lip (“bump”) engages an entry ramp in the seal bore, radially deflecting the seal lip inward, creating the contact stress required to effect a seal. In the fully installed position, the seal lips engage a straight bore above the entry ramp (see illustration). The SBMS maintains sufficient contact-sealing stress even at very low pressure. As working pressure increases, contact-sealing stresses increase, making it seal even tighter. The SBMS qualification tests were conducted with low pressure and high pressure, the fire test pass (API RP-6F “Improved”) of 2,000°F flame temperatures and 1,200°F internal seal temperature with zero leakage.
SBMS-II Seals The SBMS-II has “bumps” on the inside diameter and the outside diameter. Each seal lip engages its entry ramp, creating the sealing contact stress with the sealing diameter. The SBMS-II is used mainly as a production casing metal seal on either extended-neck mandrel-casing hangers or directly against the casing stub when slip hangers are used. When employed to seal against a casing stub, it is required to machine the casing stub after the casing is hung off. However, it requires only approximately 1 1/4˝ of the casing stub. The operation can be executed with a portable pneumatic tool. The SBMS-II is normally used on production casing where extreme temperature fluctuations are anticipated or in critical-service applications. When used against slip-suspended casing, FMC Energy Systems provides an ACME threaded casing holddown nut to minimize upward thermal expansion of the casing and act as a bit guide to protect the SBMS-II seal when running tubing or conditioning the hole. The SBMS-II seal has been used in sizes up to 20˝. Various applications of the SBMS-II design include valve stem back-seat seals, valve seat body seals and tubing hanger annular packoffs.
RCMS Seals The most recent addition to the family of metal seals is the rough-casing metal seal (RCMS). This seal design does not require special complex field machining of the casing stub; is compatible with a wide range of temperatures and corrosive environments; does not require special installation tools and is simple to install; is NACE compatible; is compatible with casing spool and tubing spool strength; and is compatible with casing string strength properties.
XEMS Seals FMC Energy Systems’ externally energized metal seal (XEMS) is used in Unihead ® wellhead systems for special mandrel casing hanger and tubing hanger applications. The externally energized seal requires mechanical force to effect a seal. The XEMS seal can be run through the BOP stack and is energized by lockdown screws or by an internal lockdown ring and running tool.
SBMS Seal
SBMS-II Seal
RCMS Seal
XEMS Seal Tubing Head
Tubing Head Adapter
Casing Stub hold-down nut
Casing Stub Hold-Down Nut
Casing Stub
SBMS
Casing Spool
Lockdown Screw
Energizing Ring
RCMS
SBMS-II
Adjustment Nut Hanger Neck
Casing Spool
XEMS Seal Ring S-Seals FS Seals Retainer Nut
S Seals
84
Mandrel Hanger
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18 3/4" metal-to-metal annulus seal assembly Casing Hanger Lock Ring
Locking Mandrel Seal Bumps
Retainer Pins
Outer Body
Unihead Lock Ring
M2M Seal Element Shear Pins
Seal Bumps
Retainer Pins
Metal-to-Metal High-Performance Seals The metal-to-metal high-performance (M2M HP) Annulus Seal Assembly seals the annular space between the Unihead and the UWD-15 Casing Hangers. The seal is preloaded at installation, giving outstanding sealing performance even at low pressures. Two seal bumps on the OD of the M2M HP seal assembly seal against a recessed groove in the ID of the Unihead. Three radiused seal bumps on the tapered ID of the M2M HP seal assembly seal against the mating tapered surface on the OD of the casing Hhanger. The seal element material is a corrosion-resistant alloy, rendering the seal assembly fit for use in carbon dioxide environments. All mating equipment is overlaid with a corrosion-resistant alloy. The seal bumps plastically deform during installation, filling scratches that may be present on the sealing surfaces. The M2M HP seal assembly OD locates and aligns within the bore of the Unihead during installation and centralizes the M2M HP seal assembly. The OD also protects the two seal bumps on the seal assembly OD from damage during installation. A square shoulder in the bore of the locking mandrel sits on top of the casing hanger. The M2M HP seal assembly is positioned in the Unihead so that the seal elements align with an undercut in the Unihead bore. This undercut area minimizes scratching or scuffing of the seal surfaces which can occur during drilling operations. When the energizing mandrel is operated, locking segments engage with a groove on the ID of the Unihead. A lock ring in the ID of the M2M seal assembly engages with a groove on the OD of the UW-D15 Casing Hangers. The M2M HP seal assembly bottom surface protects the seal by having a larger diameter that shields the retracted sealing elements during running. The M2M HP seal element is retained on the seal assembly with a retainer strip. This retainer strip is held captive and provides uniform support during seal retrieval. The M2M HP Annulus Seal Assembly is designed to prevent premature energization as the assembly is run downhole. It is rated for 15,000 psi, H2S service and 250oF service. They were successfully tested to 350oF.
Running
85
Landed
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T E C H N O L O G Y C A PA B I L I T I E S
A
Quality Product High on the list of factors influencing your choice of a wellhead vendor should be the vendor’s investment in research and development, including its testing and analysis programs and its strategies for achieving and maintaining quality – from R&D to manufacturing to aftermarket services. Ultimately, FMC Energy Systems’ commitment to technological excellence optimizes your performance and minimizes your system life-cycle costs. We’re proud of our products and have implemented processes that assure continual improvement of our technology and services and the processes themselves. When you specify an FMC Surface Wellhead system, you can be assured that every nut and bolt means a pedigree of quality.
Q U A L I T Y M A N A G E M E N T S T R AT E G I E S
FMC Energy Systems designs and manufactures products of the highest quality, guided by the strictest standards of the safety of employees and customers and the integrity of the environment. We treat quality and safety as processes that can be identified, diagrammed, analyzed and continually improved. We define quality performance as attitudes and behaviors that drive technology, operational excellence and superior customer service and ultimately add value. Our quality processes are industry-leading, developed and executed in accordance with international quality standards and practices and major classification societies. Testing and manufacturing facilities are ISO 9000 and API certified. Our worldwide quality processes assure product uniformity, reliability, performance, safety and accountability: Continuous Improvement If you measure all the defects in a process, you can systematically eliminate them and get as close to zero defects as possible. FMC Energy Systems’ reliability group focuses on performance measurement and failure prevention.
Uniform Global Standards Everywhere in the world, FMC Energy Systems follows identical quality objectives, formats and processes. We are quite literally on the same page with a single quality manual and uniform operating procedures and work instructions.
Encyclopedic Documentation The foundation of a quality system is the ability to maintain standards, archive documentation and provide global access to it. Our PDM (Product Data Manager) is an interactive database of engineering specs, quality matrix data, product standards, parts, drawings, project data, manufacturing data, quality manuals and service alerts accessible via our intranet.
86
Qualifying Suppliers Our suppliers must provide materials, products or services that conform to API specifications, customer requirements and FMC quality and safety requirements. Some 20% of our quality management resources and processes are dedicated to defining supplier capabilities and services, monitoring and measuring performance and developing quality systems with our suppliers worldwide.
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Te c h n o l o g y Capabilities
OUR QUALITY VALUES
Management commitment Continuous improvement processes Quality-improvement teams Employee education, training Global
Quality
Assurance
and recognition
FMC Energy Systems’ regional locations follow the
Plan for Zero Defects
same worldwide quality system process and format
Safety
(Quality Manual, Global Work Instructions, Operating
Customer satisfaction
Procedures and Local Work Instructions). All quality-
Execution
assurance and engineering documentation is electronically revised and controlled in a centralized product data management system. Local access through intranet ensures worldwide product standards and process control, and provides worldwide visibility and access to information.
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T E C H N O L O G Y C A PA B I L I T I E S
Engineering
Capabilities:
Design & Analysis
FMC Energy Systems’ long history of designing and manufacturing the finest surface wellhead products and providing cost-effective systems solutions speaks to our company’s commitment to developing the industry’s most advanced engineering resources and capabilities, including materials selection and finite-element analysis, supported with the appropriate R&D facilities and processes, including materials and design testing labs. The first step in the engineering process is materials selection, with the main lines of emphasis on metals, elastomers and lubricants. Metallic Material Selection
Elastomer Selection
Grease Selection
Key drivers in selecting metallic materials for
Elastomers are FMC Energy System’s
A variety of specially selected greases are
our wellheads are strength, environmental
proprietary formulations designed to
used in FMC Energy Systems’ wellhead
factors and manufacturability. Precise
perform in standard oilfield production
equipment. These greases are formulated to
assessment of production fluid chemistry
environments. Each compound is
provide excellent lubrication characteristics
is vital to the selection process. These
developed to function in a specific range
over a wide range of temperatures while pro-
analyses include breakdowns in the amounts
of temperature, pressure and aggressive
viding resistance to petroleum hydro-
of dissolved chlorides, carbon dioxide and
chemicals environment. Elastomer com-
carbons, H2S, CO2, chlorides, water, frac
hydrogen sulfide. All selections are based
pounds are qualified through rigorous test-
fluid, acids and common oilfield chemicals.
on API and NACE guidelines and field
ing on actual seal configurations. Seals are
Greases are evaluated using a variety of test
experience.
tested to anticipated worst-case conditions.
instrumentation, including autoclave expo-
They are manufactured from compounds
sure and dynamic mechanical analysis. Full-
with long life expectancy in oil production
scale field testing of products is also used to
environments. Elastomers are molded into
provide service reliability data on selected
seals that are qualified for up to 250
greases.
degrees and 15,000 psi.
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Our engineers employ sophisticated linear analyses in conjunction with rigorous, full-scale product testing to verify the accuracy of design methods. Capabilities include structural analysis, thermal analysis and computational flow dynamics. ➤ FEA (Finite Element Analysis) and CFD (Computational Fluid Dynamics) help to analyze the stress condition the equipment will be exposed to.
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T
Lab esting Capabilities E n v i ro n m e n t a l / F l u i d L a b Te s t i n g
FMC constantly monitors the compatibility of the materials used for wellhead components by experimentally exposing them to a wide range of hostile environments encountered by equipment used in oil and gas service. A variety of test instrumentation is used to simulate the effects of phenomena such as corrosion and wear, explosive decompression, chemical attack, heat aging and fluid compatibility. Metallic and nonmetallic components, materials and processes are qualified in dedicated laboratory facilities.
L i f e P re d i c a t i o n Te s t i n g
H i g h / L o w Te m p e r a t u re Cycling
FMC Energy Systems conducts life predication testing on seals and sealing materials by exposing components to elevated temperature environments containing fluid chemistry consistent with intended service conditions. Statistical data is gathered from multiple test runs and correlated to predict component life at actual service temperatures.
Full-scale product testing is conducted in dedicated cold-box test facilities in accordance with API 6A, Appendix F. Products are functionally tested to maximum operating pressure and subjected to cycles in a temperature range consistent with the application environments to which they are exposed.
ENGINEERING LAB Environmental Chambers – Temperature range –75o to + 600oF. Pressure to 22,500 psi using nitrogen gas or CO2. Test Cell/Ram Cell – Testing of products with either nitrogen gas or water. Machine Shop – Lathes, mills, drill press for fabrication and modification of test fixtures. Hydraulic Rams – Capacity of 2-million-pound pull for simulation of casing string weight, destruction pull testing. 200-Ton Press – Used to simulate installation force of elastomer and metal seals. Immersion Gas Test Tank – For submerging products for manual gas testing, verification of bubble-tight product.
Bending
FMC Energy Systems has several bending and torsion test fixtures which are used to simulate the actual service loads on connectors, such as the Speedloc. The largest fixture has the capacity to apply up to 8 million ft.-lbs. bending with 1 million lbs. tension. A smaller fixture is used to apply bending, tension and torsion simultaneously, up to 1 million ft.-lbs. bending with 500 kips tension and 500 ft.-kips torsion.
R & D L A B FA C I L I T I E S Test Annex – Ovens for ambient to +600oF for seal testing. Automated rotating stem-packing system for tests to 20,000 psi, and stem and lift nut system simulation gate drag on lifting threads. Endurance Test Cells – Automated life-cycle testing of gate valves. Temperature range of ambient to +600oF and pressure to 22,500 psi nitrogen gas. R & D Lab – Fabrication of pump systems and test stands and installation of strain gages. Control room for fire test and endurance test cells. Fire Test Facility – Fire-test qualification of products using up to six open-flame atmospheric burners (1.8 million BTUs each). Temperature range from ambient to +2400oF and pressure to 10,000 psi. Pumps – Prototype and life-cycle testing of pumps using fresh water, saltwater or bentonite. Erosion Flow Loop – Closed-loop sand slurry used to test wear of flow line products.
O U R R & D C A PA B I L I T I E S I N C L U D E :
Custom product development Exhaustive laboratory and field testing ➤ Advanced materials technology, including proprietary elastomer lab ➤ Fire-test facilities with sophisticated data output ➤ Destructive and nondestructive testing ➤ Engineering design and finite-element analysis ➤ Environment, corrosion and safety engineering ➤ Three-dimensional modeling and simulation ➤ ➤
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Elastomer
A
Ca p a b i l i t y
wellhead is as good as its valves and seals, and
performance is about seal performance. Higher pressures, well-treatment chemicals, longer frac times and other critical-service conditions place emphasis on seal integrity. If a seal failed, the budget can be severely impacted. Our customers demand the most reliable seals technology can deliver, and our industry has set new standards for seal performance. Conventional O-ring seals no longer meet application demands and industry standards. In order to maintain complete control over the quality and performance of our elastomer seals, FMC Energy Systems has made a substantial investment in an Elastomer Laboratory dedicated to the development of new and improved elastomer seal materials and designs. Field-proven designs developed by FMC Energy Systems include FS-Seals, S-Seals, and Compression Packings with Wire Mesh. At the heart of these premium seal designs are proprietary elastomer compounds formulated to provide the best combination of mechanical properties and chemical resistance to oilfield environments. Molding of FMC Energy Systems’ seal designs using these proprietary compounds is performed at our Nonmetallic Production Facility, located in Houston, Texas. Our experience has demonstrated that in-house elastomer seal manufacture and optimized compounds provide the most reliable combination of mechanical and chemical properties in a premium elastomer seal. This is in contrast to much of the oilfield industry which outsources seal manufacturing. New seal designs demanding new, improved compounds, new molding techniques and testing processes are developed in our Elastomer manufacturing and testing facilities. This assures that FMC Energy Systems brand elastomer seals are not only state-of-the-art design and materials, but rigorously tested for the complete range of customer applications and environmental operating conditions.
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AFTERMARKET SERVICES
The
S uppor t Factor
F M C S u r f a c e We l l h e a d ’s w o r l d w i d e , w o r l d - c l a s s s e r v i c e re s o u rc e m a x i m i z e s safety, performance and retur n on investment. Realizing the maximum return on your investment is a function of up-front costs, system performance and system cycle costs – all of which are linked to the quality of both the equipment and the service provided by your wellhead equipment vendor. ➤ Support for a single well or a full-field service demands performance on a par with the performance of FMC Surface Wellhead’s products and systems. ➤ Driven by your objectives of (1) operating safely, (2) maximizing well profits, (3) extending wellhead equipment life and (4) tracking and utilizing wellhead assets, FMC Surface Wellhead has developed a service resource second to none in HSE-driven safety practices, reliability, and performance. Moreover, our service technicians are deployed where you need them; in maintenance centers strategically located throughout the globe.
F M C S u r f a c e We l l h e a d S e r v i c e Te c h n i c i a n s .
We are confident that our global service
resource is simply tops in the industry. The remarkable FMC Surface Wellhead safety record (as measured one of the lowest incident rates in the industry) and retention rate supports our conviction. Given the methodical care with which FMC Surface Wellhead recruits, trains and supports our service resources, it’s no accident that our technicians are the best in the business.
1
2
OUR UNIQUE RECRUITING PROCESS.
OUR RIGOROUS TRAINING PROGRAM.
While most of the industry tends to recruit service technicians from experienced rig crews, we have followed a different path by recruiting directly from vocational schools and the military services. Technician candidates recruited from these two major sources of talent are already comfortable with formal training courses, have a disciplined approach to following procedures and have great attitudes: they are proud of their company, their skills and their commitment to safety and enjoy helping customers by providing superior service.
Before joining our service team as a fullfledged FMC wellhead technician, every recruit must complete a comprehensive 26-week training program. The curriculum includes classroom study in drilling technology and FMC Surface Wellhead products, hands-on lab and field instruction, as well as a rotation through many functional areas of the business. Above all, our service trainees have the FMC Surface Wellhead safety culture ingrained into every aspect of their thinking, planning and job performance. Before graduating, each apprentice must pass a written competency examination.
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3 S A F E T Y F I R S T, R E L I A B I L I T Y. When you call for an FMC Surface Wellhead technician, you know you’re getting someone technically competent and thoroughly experienced, trained and schooled in safety and reliability, including on-time performance. Our specialists are also skilled at resolving issues on location, which can translate into major cost savings. They perform in compliance with local regulations and FMC Surface Wellhead’s safety practices. At the conclusion of the job, the technician generates a status report that also includes Internet links to digital photos, equipment schematics and maintenance schedules.
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Aftermarket Service
FMC Surface Wellhead Services
a
Gate Valve Lubrication Ser vices Regular lubrication and maintenance of gate valves can substantially prolong the life of your wellhead system. An ongoing program of valve lubrication is simply good business, as it can reduce the frequency and cost of repairs and well shutdowns. Our technicians flush treating fluids, lubricate bearings and fill the valve body with grease for a single well (for instance, after the equipment has been exposed to corrosive chemicals) or on a routine basis as part of a total field lubrication program. On your valve lubrication maintenance calls, our highly trained and experienced technicians follow a strict schedule of procedures step-by-step to assure thoroughness and uniform service throughout the life cycle of the equipment. They are also guided by detailed reports (including photographs and schematics) that document the size, working pressure, serial numbers and manufacture of each piece of equipment on each wellhead.
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FMC Surface Wellhead Services
b
Pre-Workover Inspection S e r v i c e A well workover is no time to discover problems with the wellhead. Your FMC Surface Wellhead technicians can help prevent costly workover rig and crew downtime by identifying and documenting the installed equipment and verifying the proper functioning of all wellhead components before the rig arrives. This inspection includes tests for pressure leaks, valve inspection to assure proper functioning, prepping the bolts for fast and easy removal and any necessary repairs. Our technicians also provide test results and documentation for each wellhead as the units are scheduled for workover or moving.
c
Repair and Asset Management
you in the active management of the life cycles of
The useful life of your surface wellhead components
your wellhead equipment inventories. With FMC
often exceeds the life of your wells. Managing and
Surface Wellhead’s “cradle to grave” information
utilizing these assets throughout their life cycle can
management system, you can track every wellhead
yield significant savings by reducing or eliminating
asset from invoice to repair history to the asset’s life
the need to purchase new equipment.
and whereabouts after it is removed from the wellsite
FMC Surface Wellhead technicians help you
and placed in customer property (CP) or on to a new
extend the life of your wellhead equipment in two
wellsite to sell or scrap. With our asset-tracking
ways: (1) by a regular schedule of maintenance and
system, you can track and manage every component
prompt repairs for all the components of your
of every installed wellhead system or CP inventory on
wellhead and keeping them in top working order, or
your laptop from anywhere in the world.
returning them to peak condition, and (2) supporting 94
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I N S TA L L AT I O N A N D S E R V I C E T O O L S
Installation and
[
S ervice Tools
A major contributor to FMC Energy Systems' unsurpassed record of safety is the quality, performance and reliability of our service tools. Designed with the safety of our service engineers in mind as well as the functionality of the equipment, FMC Energy Systems' service tools ensure the industry's safest and most efficient wellhead installation and maintenance.
Service
tools and
designed
for
safety
functionality
Bore Protectors F e a t u re s a n d B e n e f i t s ◆ Straight-bore bore protectors are compatible with all C-22 and C-29 casing heads and spools and with all straight-bore FMC Energy Systems tubing heads and Uniheads®. ◆ Bore protector can be secured in a bowl by EG grooves or by lockdown screws to protect against wear and tear during drilling. ◆ Protectors are installed and retrieved with J-type running tools. For 10- through 20-inch nominal protectors, the FMC Energy Systems combination test plug/running tool can be used.
WHEN ORDERING,
specify the following:
A. Nominal Bowl Size of Head or Spool B. Type of FMC Energy System Casing Head, Casing Spool or Tubing Head C. Inside Diameter of Bore Protector D. Drill Bit Size
C o m b i n a t i o n B o r e P r o t e c t o r R u n n i n g To o l a n d B O P Te s t P l u g F e a t u re s a n d B e n e f i t s ◆ Versatile tool that runs on drill pipe with pin either up or down. With pin up, installs and retrieves FMC Energy Systems bore protectors (10- through 20-inch sizes only). With pin down, it lands and seals in the head or spool seal bore for the pressure testing BOP stack or manifold connections. ◆ Bushings are used to adapt the basic tool to different sizes. ◆ Drill pipe can be suspended below the test plug, eliminating the need to trip all pipe out of the hole.
WHEN ORDERING,
specify the following:
A. Nominal Bowl Size of Head or Spool B. Type of FMC Energy System Casing Head, Casing Spool or Tubing Head C. Tool Joint Thread Required
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B o r e P r o t e c t o r R u n n i n g / R e t r i e v i n g To o l ◆ ◆
A basic J-type tool that runs on drill pipe. Locks into bore protectors with a quarter-turn right, releases with a quarter-turn left. Available for all sizes of bore protectors.
WHEN ORDERING,
specify the following:
A. Nominal Size of Bore Protector to Be Run B. Tool Joint Thread Required
B a s i c B O P Te s t P l u g ◆ ◆
A simple test plug that runs on drill pipe. Available to fit all FMC Energy Systems casing heads, casing spools and tubing heads.
WHEN ORDERING,
specify the following:
A. Nominal Bowl Size of Head or Spool B. Type of FMC Energy System Casing Head, Casing Spool or Tubing Head C. Tool Joint Thread Required
Va l v e R e m o v a l P l u g s a n d L u b r i c a t o r s ◆
◆
◆
◆
Lubricator installs VR plugs in casing head, casing spool or tubing head side outlets so gate valves can be isolated from pressure for removal or repair. Lubricator mounts on the gate valve outlet flange. With the lubricator holding the pressure, the gate valve can be opened, allowing the VR plug to pass through the valve and be threaded into the head or spool outlet. All studded and flanged outlets on FMC Energy Systems casing heads, casing spools and tubing heads are threaded to accept VR plugs. VR adapters are available for threaded outlets. For outlet working pressures of 15,000 psi, straight-thread, metal-tometal seal VR plugs are standard. For lower working pressures, tapered-thread VR plugs are standard.
Note: For ordering details, consult your nearest FMC Energy Systems representative.
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S t a n d a rd , t a p e re d - t h re a d VR plug
S t r a i g h t - t h re a d , h i g h - p re s s u re VR Plug
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I S - A Tr e e Te s t P l u g ◆
◆
I S - A B a c k - P r e s s u r e Va l v e
Similar to the back-pressure valve, but with the seat and stinger arranged to hold pressure from above, sealing the tubing bore against tree test pressure. Test plug installs exactly the same way as the back-pressure valve. Since the plug will not hold pressure from below, well pressure must be isolated from the tree using a downhole plug or SCSSV.
◆
◆
◆
◆
Latches into mating groove in TCSeries tubing hangers or couplings to seal the well bore while the blowout preventers are removed and the tree is installed. Also used to temporarily isolate the tree from well pressure for repairs without killing the well. Installed by hand or by hydraulic lubricator. Shear pin release provides positive setting indication. Seals in hanger or coupling where strength is maximum and dimensional tolerances are controlled, not in tubing. Valve cannot accidentally pass into tubing. Internal stinger makes it easy to check well bore for pressure, or to equalize pressure across the valve.
B a c k - P r e s s u r e V a l v e / Tr e e Te s t P l u g L u b r i c a t o r s ◆
◆ ◆
With the FMC Energy Systems lubricator, the IS-A back-pressure valve or tree test plug can be installed and retrieved, hydraulically, through a Christmas tree under well pressure. Each lubricator has accessory parts that adapt it for most tubing sizes and Christmas tree working pressures. Hydraulic remote operated to enhance safety conditions.
Note: For ordering details, consult your nearest FMC Energy Systems representative.
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V
Our Core alues
FMC
Energy
Systems
◆
Our goal is continuous improvement.
◆
Risk management (hazard controls, behaviors) and pollution prevention are the focus.
◆
All occupational injuries/illness and environmental incidents can be prevented.
◆
Line management is responsible and accountable for HSE.
◆
Employees are involved in HSE programs and activities at all levels of the organization.
◆
Working safely and with regards for the environment are conditions of employment.
◆
HSE management and efficient production are equal.
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