CASE STUDY OVERVIEW
An onshore natural gas producer in Brazil required custom wellhead control panels to support a multi-well drilling and production program tied to long-term natural gas infrastructure operations, part of PHC’s broader work supporting oil and gas operators with safety-critical control systems. This particular field uses traditional vertical and directional wells, targeting the porous sandstone reservoir formations at measured depths of approximately 6,500ft.
The onshore producer had previously sourced wellhead control systems through a larger industry supplier but sought a more responsive partner capable of delivering higher-quality, custom-engineered solutions at a more competitive cost. The project also required modifications to address evolving operational requirements, including ASME-certified components and fail-safe control functionality improvements.
Pneumatic and Hydraulic Company (PHC) designed, engineered, fabricated and tested two custom wellhead control panels tailored specifically to the customer’s operating environment and production requirements. The turnkey solution included custom panel design, detailed schematics, documentation packages, testing and overseas delivery support for deployment in Brazil.
The project demonstrated PHC’s ability to deliver highly customized, safety-critical control systems for international oil and gas operations through improving reliability, responsiveness and long-term operational performance. This successful project resulted in the award of two additional wellhead control panel jobs from the customer.
PROJECT SCOPE
The onshore natural gas producer operates integrated production and infrastructure assets supporting onshore drilling in Brazil. As part of an ongoing multi-well program, the company required wellhead control panels to support safe production and emergency shutdown functionality across new wells.
These wellhead control panels serve as a critical part of the wellhead safety system, monitoring and controlling production equipment while providing emergency shutdown capabilities in the event of operational abnormalities or catastrophic well conditions.
The onshore producer had previously sourced similar systems through a larger supplier relationship, but experienced concerns related to cost, customization flexibility and overall product quality. Previous systems relied on more standardized modular approaches that did not fully align with operating requirements or long-term performance expectations.
The operating environment and project scope introduced several critical operational and engineering requirements:
- Safety-critical control infrastructure supporting active natural gas wells with depths of ~6,500ft
- Design for long-term outdoor operating environment with exposure to high heat, humidity and corrosive field conditions
- Corrosion-resistant design considerations for international field deployment
- Detailed engineering documentation and schematics
- Design flexibility from evolving project specifications
- ASME-certified tanks introduced during the project lifecycle
- Overseas logistics and air freight coordination for delivery to Brazil
- Fail-safe control functionality improvements
The customer discovered PHC through online search efforts. Industry expertise, responsiveness and a highly customized engineering approach quickly established trust early in the evaluation process.
TURNKEY SOLUTION
PHC engineered and delivered a fully customized wellhead control panel solution specifically designed around the operator’s objectives, safety requirements and field conditions. Unlike standardized modular systems commonly used in portions of the industry, PHC used a consultative engineering approach focused on understanding the customer’s operational goals, existing system concerns and long-term production requirements before finalizing the design.
The turnkey solution included:
- Custom-engineered wellhead control panels
- Complete panel design and layout engineering
- Detailed schematics and documentation packages
- Bill of materials development
- ASME-certified tank integration and documentation
- Fail-safe solenoid control improvements
- Corrosion-resistant design considerations
- Fabrication, assembly and testing
- Overseas shipping preparation and logistics support
PHC also reviewed previous system drawings and identified opportunities to improve functionality, simplify operation and enhance reliability. During the second phase of the project, additional modifications were incorporated based on customer feedback and operational preferences identified after installation of the first two panels.
IMPLEMENTATION
Engineering Evaluation and Design: PHC reviewed the customer’s previous control panel configurations, evaluated operational requirements and developed a fully customized design tailored to the application.
Collaborative Review Process: Detailed schematics and engineering documentation were shared with the customer for review and feedback, allowing operational personnel to request adjustments before fabrication.
Fabrication and Assembly: PHC managed panel fabrication, assembly, testing and documentation development internally as part of the turnkey execution model.
Specification Modifications and Compliance Support: During the project, additional ASME certification requirements were introduced for tank components. PHC adapted the design and documentation package to support the updated requirement.
Testing and Delivery: The completed systems underwent testing prior to shipment and were prepared for international delivery to support the customer’s drilling schedule in Brazil.
Startup and Operational Support: Following installation, the customer reported a smooth startup process and successful commissioning with no significant operational issues.
OUTCOMES
The custom-engineered wellhead control panels provided the customer with a highly responsive, safety-focused alternative to previous systems while supporting ongoing natural gas production expansion efforts.
Earned repeat business: Following successful startup and operational performance of the first two panels, the customer returned to PHC for two additional wellhead control panels supporting continued drilling expansion.
Turnkey execution: PHC managed engineering, design, fabrication, testing, documentation and delivery as a single-source solution.
Improved customization: The fully customized approach allowed the system design to align more closely with operational goals and field requirements.
Enhanced safety functionality: Fail-safe control improvements and engineered modifications strengthened system safety and operational reliability.
Regulatory adaptability: PHC incorporated evolving ASME certification requirements during the project lifecycle without disrupting delivery.
Strong customer partnership: The customer provided positive feedback following startup and commissioning, noting the installation process was smooth and trouble-free.
Specifically-engineered for the customer’s operating requirements, safety objectives, and field conditions, these wellhead control panels outperformed standardized modular systems commonly used within the industry.
Pneumatic & Hydraulic Company supports oil and gas operators with custom-engineered control systems, fluid power technologies and turnkey automation solutions designed for demanding operating environments. From wellhead control systems and process control infrastructure to customized hydraulic and pneumatic solutions, PHC delivers engineered solutions for uptime-critical industrial operations where safety, reliability and performance matter most. Learn more at pneumaticandhydraulic.com.