Professional Documents
Culture Documents
INDEX
1. Mecha Controls your partner in Wellhead Systems
Company information
4. ATEX
7. Various Products
7.1. Test Units
7.2. Control Units
7.3. Local Stations
7.4. BOP Control
7.5. Power Skids
7.6. Solar
7.7. Small Engineering
7.8. Modifications
7.9. Transport
9. Reference list
10. Pictures
Company Information
Mecha
Controls
B.V.
Established 2000
Liability Insurance Royal & Sun alliance global & large risks
Program
Petraglobal bv.
Coenecoop 103-105 Zone(s):
2741 PH
Waddinxveen All units can be designed to operate in any specific
The Netherlands zone.
tel.: +31 182 302897 Eex-e; Eex-d or Eex-I are well known terms and our ex-
fax.: +31 182 302895 perience and selections of components will generate a
design that will fulfill all needs.
homepage: www.petraglobal.com
E-mail: info@petraglobal.com
Interest:
Usage: Company:
Units will be designed in detail influenced by
Quick testing of pressure settings.
customer with maximum working pressures up Quick testing of applications before installation
Contact name:
to 10.000 psi (690 bar), with use of specified Back-up power for emergency situations Address:
components according customer requisition.
ZIP code:
Otherwise standard of the shelve components Any other feature can be added at customers request.
with proven reliability are used to guarantee City:
Test Unit:
quick response times at eventual malfunctions. 7 bar max. pneumatic input, Country:
690 bar max. output, Tel:
30 liter reservoir,
Services: 1-24 Hours pressure recorder, Fax:
High volume pump for quick fill
and second high pressure pump E-mail:
Commissioning and field start-up activities;
to reach max. test pressure.
Advise and selection of components in case of Very easy to operate and hand carry for two persons.
repeating malfunctions;
Assistance with demounting instrumentation at Usage: Power units (reply to Petraglobal)
Installing spare parts: are some examples of the Testing of completions. Engineering
Others.:
personnel with all certificates and safety train-
Power Unit:
ings are stand-by to cover your requirements.
Any input source; pneumatic / electric
Engineering: 690 bar max. output, Additional Information:
Reservoir will be calculated at min. volumes needed.
Pumps will be selected at flow and available power,
In house engineering guarantees a reply within a Communication with customer at high level to be
week, our company has a flat structure that has no sure that all options needed will be included.
typical mountains to over win to make decisions.
Electrical related issues are done by a third party Usage:
Any operation or testing of a specific valve.
contractor.
Single Power units with multiple operating
Please give us a try and fill in the reply form units possible.
attached to this brochure.
Any other feature can be added at customers request.
Spare parts:
Monitoring Unit:
Large companies spend much time at searching for Any input source;
the right component, related vendor and pay for pneumatic / hydraulic / gas
small order fees and handling charge. Local read-out and control at
Mecha Controls can help you to obtain the compo- wellhead area.
nents. Most suppliers are delivering on a weekly
Usage:
bases to our workshop. We can offer you spare Local wellhead pressure read-out.
parts against a small commission fee without small Local emergency control.
order and handling charges.
Wellhead Systems Catalogue
Furthermore, we collect used and waste oil at customer locations and assure correct
disposal . We have all necessary documents.
All new employees are informed using HSE-guidelines in their first days of employment.
They must sign for acknowledgement.
All visitors sign in at the entrance. A flyer with all basic rules is available in both English
and Dutch. Escape routes, first aid kit and fire extinguisher are shown on drawings on
the wall in case of calamities.
3.2 Quality
Mecha Controls has VCA** certification; a local safety checklist implemented by a
group of companies in Rotterdam Seaport Area.
We are dedicated to certify according to ISO 9001:2000 standards in 2005, which will
be extended to the self certifying stage of ATEX certification.
An electronic system called RMS is used to store all customer information that will be
used to help, find, and witness the customer on a quick and decent way, such as:
Quotation registration
Visit reports
Complaints
After sales / follow up
Mecha Controls seeks to increase its quality continuously. All experiences at our
different projects are therefore communicated and stored in an electronic system. This
also results in quicker response times.
For all our projects we keep variation forms, on which changes and improvements are
recorded.
3.3 Workshop
Our 400m2 workshop is equipped with all necessary materials to handle large projects.
Each year we manufacture approximately. 30 HWCUs for end-user NAM. Planning and
logic is performed in detail resulting a quick flow from supplied materials into finished
and tested control panels.
Small repairs can be done in-house using a TIG welding machine. This will reduce
production down time waiting for suppliers action.
Tubing and saw are located in one area in order to facilitate assembly.
4 ATEX
Within the European Union various rules and regulations were combined into one new
regulation named ATEX (Atmosphres Explosibles). Since July 2003 all products must,
by law, be designed and manufactured according to this new ATEX directive, which has
been in effect since 1996.
Former directives were restricted to electrical equipment for hazardous areas, and were
strictly based on technical standards regulated by test authorities.
Equipment that complies with the new directives may carry the CE mark.
Up to the ATEX live date, free movement of goods for hazardous areas, was indicated
by the distinctive community mark EX. Since July 1st, 2003, only products carrying the
CE mark may be put on the market and put into service. Through the application of the
conformity assessment procedures, manufacturers can issue an EC Declaration of
Conformity, stating the compliance with the relevant directive(s) and apply the CE mark
on their equipment. The EX will still appear on the label, but its only function is to
indicate that the product is intended for use in potentially explosive atmospheres or is
contributing to its safety.
Mecha Controls implemented this new regulation from the beginning, and assigned a
third party to help implement the new rules. A list of dedicated third parties can be
found at the end of this section. The four digits can be found in the marking behind the
CE mark.
Essential safety requirements (cover a wide field, fully detailed in Annex II of the new
directive):
- integrated safety principle;
- specific conditions of inspection and maintenance;
- environmental conditions;
- marking;
- instructions for use;
- choice of materials;
- design and manufacturing;
- potential ignition sources, such as sparks, flames, electric arcs, high surface
temperatures, acoustic energy, radiation (optical, electromagnetic or other
sources);
- risks caused by software;
- explosive atmospheres caused by the presence of gas, vapours, and mist;
- explosive atmospheres caused by the presence of air-dust mixtures.
Equipment covered by directive 94/9/EC must also meet the requirements of other
relevant directives:
- Electromagnetic Compatibility Directive (EMC);
- Machine Directive.
Selection:
Zones:
Temperature class:
Temp.class T1 T2 T3 T4 T5 T6
Gas Groups:
Mines I Methane
II B Ethylene
II C Hydrogen
Acetylene
Protection concepts:
Pressurised Eex-p 2
Encapsulation Eex-ma 1
Category M1 M1
Marking:
All equipment and protective systems must be marked legibly and indelibly with the
following minimum information:
Marking example:
CE marking
Identification number of notified body
Use of equipment in potentially explosive atmospheres.
Equipment Group
Equipment category
Gas-group
Protection class
Temperature class
Introduction
The typical name already explains the function of the type of equipment we
design, manufacture, and sell: the HWCU controls, with the necessary pressure,
the safety valves of a production wellhead.
The wellhead is a production tree that enables people to produce oil and gas
safely from reservoirs located deeply underground.
A typical wellhead is equipped with at least two safety devices. This is not only
necessary, but also obligated under general laws. These two safety devices are
the Surface Safety Valve (SSV), and the Surface Controlled Subsurface Safety
Valve (SCSSV). The SSV is located at the surface mounted in the X-mas tree.
The SCSSV on the other hand, is located subsurface at depths between 100 and
600 metres. Both new and existing production platforms have options like wing
valves, choke valves, etcetera.
Most of these valves are controlled by hydraulic power; only a few, mainly the
SSVs, are controlled by pneumatic power.
A typical HWCU has at least two sections. The first is a power section which
generates control and system pressure. Furthermore, the HWCU, has one or
more sections containing controls to open and close the valves.
For the HWCU a variety of power sources, in various combinations can be used.
Many of these combinations have already been designed, and are now fully
operational at various production sites. A combination of the following power
sources is possible:
- Hydraulic power : oil, water;
- Pneumatic power : instrument air, production gas, N2;
- Electric power : 380 Vac, 24Vdc, Solar energy;
- Hand power.
Of course, there are both advantages and disadvantages in using the various
power sources. The various characteristics can be summed up as follows:
Pneumatic/hydraulic:
- a compressor is needed;
- pneumatic pumps need big air flows;
- pneumatic pumps need regular maintenance;
- noise production is high;
- additional tubing and components needed for air treatment;
- sensitive for low temperatures;
- parts are relatively cheap;
- safe to use in hazardous areas.
Electric/hydraulic:
- no compressor needed;
- electric motor pump combinations are maintenance free;
- start/stop must be controlled by electric logic;
- more expensive, since low hydraulic control power must be generated
for controls;
- low noise production;
- not sensitive for low temperatures;
- parts are relatively expensive;
- Ex parts needed in hazardous areas.
The units are designed to control multiple wells, using power generated by one single
power section. Outputs are taken from this main power section, and divided over the
various control sections, thus enabling the operator to control the wellhead.
Reservoir sizes are custom made, to fit each customers individual requirements. For
maintenance purposes, a lift off hinge back door is installed. Control panel and devices
are located behind front doors with lexan windows. The doors can be opened up to 90
degrees. The amount of safety valves and electrical devices that can be controlled is
unlimited.
A combination of all available power sources, as discussed earlier, can be used for the
MWCU.
There are three standard designs, which comply with most requests. Very short
delivery times can thus be realised.
Of course, all our Single Well Control Units can be custom built, to meet your specific
requirements.
7 VARIOUS PRODUCTS
This range of products is mostly used to generate a pressure output that can be
blocked and recorded.
In a typical design, two pumps, one for quick fill at low pressure, and one to produce
the higher test pressure, are placed. This can be pneumatic, electric or fluid controlled.
Reservoir sizes are custom made, with a minimum of 25 litres up to 400 litres. They are
equipped with: filler/strainer, inspection/cleanout hole, drain connections, level gauges
and other features requested like for instance level alarms.
Output is a pressure chart showing functioning of the tested equipment. This can be
done with use of a mechanical recorder with pens and a paper chart or digitally using a
Honeywell logical recording device that can be read with use of a computer. Charts can
be stored and printed.
The enclosures are designed to meet end function; offshore units will be tested and
delivered according the applicable specifications. Calculations, materials selection and
welding inspections will be conducted and documented.
The skid and the reservoir are built of stainless steel. Other materials are available
upon request.
All materials used are selected at proven reliability; spare parts are available through
our worldwide distributors network. Detailed information is contained in the IOM
manuals delivered with the equipment.
Control units combine a variety of customer specific solutions. Any logical function that
can be generated with hydraulic or pneumatic signals can be translated by Mecha
Controls into a custom built unit containing all features requested.
We will design and manufacture a unit that suits your specifications perfectly.
Any valve control upto 15.000 psi is possible and there is no limit in size or complexity.
The above unit, for instance, combines BOP control, SWCU, and chemical injection.
7.3
Simple skids up to 690 Bar can be used to test and set the
switch point of pressure switches or pressure transmitters.
They can be manufactured with a combination of
pneumatic/hand operated pumps, protected with a relief
valve. This skid has a small reservoir of approximately 5
litres with filler/vent and sight glass. A bulkhead output
controlled with a block valve and indication gauges for air
pressure and output pressure will be enough to have a
pressure source available were needed.
This unit is fed with 380Vac, has its own Eex-d motor control
unit and has eight 210 bar maximum outputs. It contains a
200 litres reservoir and is equipped with low level alarm that
generates a motor stop at 10% remaining fluid. An
accumulator can be installed for emergency backup with an
additional hand pump.
7.6 Solar
Mecha Controls also has hands-on experience with solar power.
For the In-Salah gas fields in Algeria we engineered a solar unit that powered various
electric consumers on the plant. A total of 300 Watt was guaranteed for 3 hours back-
up.
7.7 Relays, PLC, indicating lamps, contactors, internal lighting and terminals
for interconnections were mounted in a logical and maintenance friendly
way.
Our engineering department has over 10 years of experience in the Oil and Gas
Industry in both practical and technical solutions. This knowledge can be found in the
products manufactured, as both are implemented in the overall design.
Quotation requests are screened upon receipt and within two days eventual questions
and suggestions will be discussed with customer.
Mecha Controls engineering is also used for large projects and we sometimes join in
temporary project teams for brainstorm sessions.
Engineering for small solutions is also a very challenging activity, which is often
performed at customer location.
Simple and quick solution are designed by Mecha Controls at customers specific
request, for instance:
Complex MCC units in Eex-d enclosure;
Indication device for a hand-valve;
Tubing and support
Hand-valve lock
High pressure filter assembly
7.8 Modifications
Existing units delivered by Mecha Controls or any other supplier can be adjusted to
meet new regulations (for example ATEX), or any other reason that makes an upgrade
necessary, for instance:.
Mecha Controls is your partner using engineers with field experience to come with a
quick solution that minimizes downtime of the equipment.
7.9 Transportation
The final product can be packed and shipped by Mecha Controls.
Examples below show a project we manufactured, packed and shipped for In Salah
Algeria. We supplied 26 Solar powered systems. Each location was assigned with a
colour code and each single system had to be packed with all materials needed for one
wellhead.
Logic, common sense, and planning were used to allow all parties meet the deadline
for shipment. We succeeded and time was left.
Second trial, split package to prevent shipping air. And second package containing all solar parts.
Our facility in Kuala Lumpur (Malaysia), can use local staff in combination with Dutch
specialists to perform services in the Far East
8.2 Personnel
All personnel are highly qualified, well-trained, and capable of working in hazardous
areas, meeting all necessary safety requirements.
The Personal Safety Log contains all necessary stamps and information needed to
enter all plants.
Maintenance and service is performed using all necessary safety precautions and
materials.
Our personnel may also be employed on a temporary basis at your site, i.e. to fill up
holes in project planning or when a deadline needs to be met.
8.3 Parts
The following brands are used within our products and selected at proven reliability.
Spares are kept on stock to fulfil quick response times. Mecha Controls is often used to
find and to supply spares to customers. We have excellent contracts that save money
in research and communications. Mecha Controls provides this service at low cost
Function:
Outputs and control for:
ROV 3000 psi max.
SSV; 6.000 psi max.
SCSSV; 10.000 psi max.
Hydraulic pressures are generated
with electric driven motor-pump
combinations controlled by MCS (by
customer) through pressure switches
with manual back-up hand pump.
This unit is designed to control the SSV and SCSSV of max. three wellheads, and
supply of the control pressure to the local ROV control panel (by others).
All internals are located such that easy maintenance can be performed. Tubing is
neatly routed and supported.
This unit is designed to control a maximum of four wells with two safety valves up
to 10.000 psi max. Picture shows one slot filled and three additional free slots.
Rear view, with opened doors. Module drawer, control section per well.
2002
Halliburton Celle
EWE AG
2
Control panel
2002
Halliburton France
Geostock
1
SCSSV controls
Wellhead Systems Catalogue
This unit is designed to control a maximum of nine wells with one safety valves up
to 10.000 psi max. Picture shows one slot filled and three additional free slots.
This unit is designed to control a maximum of six wells with one safety valves up to
10.000 psi max. Picture shows three slots filled and three additional free slots.
Control Module
Customer: NAM (EP Europe)
Function:
Module section that fits in a MWCU,
each module is able to operate the
valve of one well. Open / close
control by pull/push buttons of the
SSV and SCSSV with pneumatic
logic. The SSV is equipped with
manual override.
This unit is designed to control a maximum of two safety valves up to 10.000 psi
max. Easy well expansion can be done by adding this section in a MWCU unit.
Detailed view from the side. Detailed view from the rear.
S.W.C.U.
Single Well Control Unit
Function:
Eex-d motor controlled (with PLC
logic). unit to operate one SCSSV,
hydraulic pressure is generated by an
0,55kW Eex-e electric motor-pump
and a hand-pump is installed for
manual back-up.
This unit was designed to control one safety valves up to 6.000 psi max. A shun-
shade is mounted to protect the electronics for high temperatures.
Function:
The left section controls two safety
valves, hydraulic pressure is
generated by a pneumatic pump and
a hand pump is installed for back-up.
This unit is designed to control a maximum of two safety valves up to 6.000 psi
max. An accumulator is installed for one emergency operation of the SSV.
All controls behind a (90 max. opening) Maintenance side at the back.
lockable door. Left part is isolated and heated at 10
degrees max.
Cable support and panel through with use 34 Panels ready for inspection.
of Roxtec compression blocks.
A-style Unit
Single Well unit
Function:
This unit controls a max. of 2 safety
valves, powered by pneumatic pumps
with manual back-up, ESD button and
fusible plug output are some
additional features installed.
This unit was designed to control a maximum of two safety valves up to 10.000 psi
max.
A-style Unit
Single Well unit
Funtion:
This unit controls 1 safety valve,
pneumatic pump with manual back-
up, ESD button, fusible plug and 4-
20mA output for remote indication are
some features installed.
This unit was designed to control one SCSSV with 10.000 psi max. delivery within
two weeks and ATEX certified.
A-style Unit
Single Well unit
Function:
This unit controls 1 safety valve,
hydraulic power is generated by a
pneumatic pump with manual back-
up. ESD logic and fusible plug are
additional sensing outputs.
A 20 Ltr reservoir is equipped with
level gauge and filler.
Cabinet is made of SS 316 2mm. with
a coated standing frame.
Valves are covered with a lockable
door.
Simple maintenance can be done by
removing the cover.
This unit is designed to control a maximum of one safety valve up to 10.000 psi
max. Fully approved according ATEX.
Last minute modification, adding a The old unit, replaced by our SWCU.
pressure transmitter.
Function:
Hand operated unit that opens and
control one valve without any external
source. Ideal for small locations were
no other power sources are available
than man power. Low pressure trip
and fusible plug ESD are additional
features installed.
This unit is designed for local opening of one SSV valve with a max. of 5000 psi.
Power Unit
Customer: Halliburton Emmen
Client: NAM (EP Europe)
Function:
The power unit supplies a max. of
3.000 psi hydraulic pressure to local
control panels.
The Eex-d motor starter panel is
controlled by pressure switches. The
150 Liter reservoir is equipped with
low level shutdown.
Test unit
Customer: Halliburton Celle
Description:
Installation and engineering on the
job to connect a test unit with local
waste reservoir.
Function:
Testing completions with water based
fluid.
This unit is designed for testing purposes; quick fill at low pressure, final testing at
high pressure.
Test container, fitted with 12cm thick Local reservoir in test container
oakwood. for collecting quick dump return.
Dual filter set to maintain
cleanliness level.
Function:
This unit has combined functions to
control and overrule the WHCP when
jobs are done at the wellhead. It is
part of a more complex system and
receives hydraulic pressure from
external sources.
This unit was mounted with the All connections are located at the
backside against a wall of an office bottom, engraved text plates indicates
container. output description.
Function:
Local read of the wellhead pressure,
and local trip set-point low and high
with automatic shut in the well.
Local ESD / reset function.
This unit is designed for local ESD functions at the well area.
Function:
Local read out of the ESD status
pressure.
Local and remote ESD / reset
function.
This unit is designed for local and remote ESD functions at the well area, it can
fixed with a 2 pipe support at the bottom. Other mounting facilities are available at
customer request.
W.H.I.P.
Well Head Instrument Panel.
Function:
Local readout of valve supply
pressures.
Local operation of the valves
using Ex pushbuttons
Local override of the SCSSV.
Function:
This unit is designed according
EN10279 for Offshore usage, tested
and certified with use of third party
Lloyds.
This unit is equipped with an 7.5kW
Eex-e electric motor controlled by an
Eex-d rated full automatic controller.
A pneumatic pump is installed for
back-up. Audible alarms are
generated at low oil level, low system
pressure and low pneumatic ESD
pressure.
This unit is designed to control the rams and shears of a BOP stack. In case of
emergency the tubing will be clamped, sheared and released to shut in the well to
prevent it for a blow out. The stored hydraulic oil in the accumulators generates
enough force to perform a double action.
Load test done at 1.5x unit weight. Drop test done at 1.2x frame weight.
Pump skid.
Function:
The pump skid is able to control one
single valve using a hand-operated
pump with direct control using a 3-
way valve.
Old unit was send for repair but we The unit is complete delivered with a
suggested a complete make over, hose set and high pressure quick
quoted and customer decided. couplings.
Description:
Installation and engineering on the
job to connect a torque machine and
power unit located in two separate
containers, as well as installing and
delivery of a compressor unit with air
supply line to all containers.
Function:
Test unit to charge and pressure
recording of completions.
Output:
Water based fluid with a max. of
10.000 psi.
The containers are designed by
customer with detailed influence of
Mecha Controls.
This unit is designed to charge and test completions before they are runned into
the wellhead. A Weatherford torque-machine, with hydraulic power generator is
installed and connected by Mecha Controls.
A combination and interconnection is made through three separate containers.
Container one: Office container, with local storage of spares, kitchen and the
power-unit section.
Container two: Power container, with air compressor, electrical supply unit and
hydraulic power unit.
Container three: Test container.
Container four: Torque machine and tool container.
Hoses are easy to exchange. But not looking very neat and difficult to trace.
Air compressor with aluminium piping with various take off points.
Description:
Installation and engineering on the
job to connect a torque machine and
power unit located in two separate
containers, as well as installing and
delivery of a compressor unit with air
supply line to all containers.
Function:
Test unit to charge and pressure
recording of completions.
Output:
Water based fluid with a max. of
10.000 psi.
The containers are designed by
customer with detailed influence of
Mecha Controls.
Many pipes to bulkhead plate to be Bulkhead plate at the torque container with lines
connected to the test container. going to the torque-machine.
Modification Example I
Customer: Doedijns
Description:
Test unit 3.000 bar max.
Action:
Total upgrade, cleaning, repair and
functional test.
Replacement with a new 316SS
control plate.
Modification Example II
Customer: Expro Group
Description:
Override unit
Action:
Total upgrade, cleaning, repair and
functional test.
Installed brackets to secure the
accumulator.
Description:
Power unit
Action:
Installing check valves in a panel
supplied by others to protect the
valves against back-flow.