Wellhead operation automation

Technical Specifications – Wellhead Operation Automation System

Wellhead Control Panel (WHCP) – Core Specifications

Parameter	SJ Petro Specification
Wellhead Standards Compliance	API Spec 6A (21st Ed.), ISO 10423, NACE MR0175
Safety Standards	API 14A (downhole safety valves), API RP 14B (subsurface safety valve systems), API RP 14C (safety systems for offshore production), IEC 61508 / IEC 61511 (SIL‑2, SIL‑3)
Number of Wells Controlled	Single‑well (dedicated) or multi‑well (1–24 wells per master panel, expandable)
Control Valves	SCSSV, SSV, ESDV, wing valve, choke valve, HIPPS
Pressure Output Range	0 – 30,000 PSI (0 – 207 MPa) – higher on request
Hydraulic Working Pressure	Up to 20,000 PSI for downhole valve control
Operating Temperature Range	Standard: -40°C to +60°C (-40°F to 140°F); Arctic: -45°C
Storage Temperature	Up to +85°C (185°F)
Enclosure Protection Rating	IP66 minimum (dust‑tight, water‑tight)
Enclosure Material	304SS or 316SS stainless steel
Explosion‑Proof Rating	Exd II BT4 (Zone 1/2), higher on request
Fusible Plug Temperature	160°F (71°C) to 281°F (138°C) – field configurable
Controller Type	Industrial‑grade RTU with integrated PLC functions, 32‑bit, real‑time multitasking
I/O Capacity	Configurable up to 64 analog inputs, 128 digital inputs, 64 digital outputs per panel (expandable)
Sampling Rate	Up to 10 points/second
Data Historian	Embedded, 1‑year archive (expandable)
Local HMI	7″ – 15″ sunlight‑readable touchscreen (optional), physical ESD buttons
Safety Integrity Level (SIL)	SIL‑2 or SIL‑3 capable (IEC 61508/61511)
Supported Protocols	Modbus RTU, Modbus TCP/IP, DNP3, IEC 60870‑5‑104, OPC UA, MQTT
Physical Communication	4G/5G cellular, satellite (Iridium, Inmarsat), fiber, radio, Ethernet
SCADA Integration	Emerson, Siemens, Schneider, ABB, Rockwell and others
Power Options	Grid (110/220 VAC + battery), solar (<50 W + battery bank), hybrid
Well Types Supported	Oil wells, gas wells, injection wells, water disposal wells, geothermal wells
API Monogram	Available on request for API 6A components
Certifications	API Q1, API 6A, ISO 9001, ISO 14001, ISO 45001, CE, ATEX, IECEx

Actuator Options

Actuator Type	Pressure Range	Best For	Fail‑Safe Mode
Hydraulic	Up to 20,000 PSI	Large‑bore high‑pressure valves, fail‑safe critical service	Close on loss of pressure (spring‑return or hydraulic accumulator)
Pneumatic	80–150 PSI	Remote sites with compressed air, moderate pressure valves	Close on loss of air supply (spring‑return)
Electric	N/A	Precise control, adjustable chokes, remote setpoint changes	Spring‑return or battery backup close on power loss
Solar / Off‑Grid	N/A	Remote wells without utility power, unmanned locations	Integrated battery backup for autonomous operation

Applications – Where Our Wellhead Operation Automation Excels

• Onshore conventional oil & gas fields – replace manual wellhead checks with remote real‑time monitoring, automated production data collection and immediate alarm notification.

• Offshore production platforms – reduce personnel exposure in hazardous areas, manage wellhead safety shutdown systems and integrate with platform DCS.

• Unconventional (shale / tight) fields – monitor and control dozens of wells from a central pad equipment building, reduce truck rolls and optimise production through automated intermittent well control.

• High‑pressure, high‑temperature (HPHT) wells – API 6A components rated to 20,000 PSI, SIL‑rated ESD logic, sensors up to 250°F (121°C).

• Remote & unmanned well sites – solar‑powered WHCP with cellular or satellite communication, autonomous ESD, low maintenance and 5–10 days battery autonomy.

• Enhanced oil recovery (EOR) / injection wells – remote adjustment of injection rates based on reservoir response, real‑time pressure monitoring to avoid formation damage.

• Abandoned well monitoring – low‑cost solar WHCP with pressure and gas detection meets regulatory surveillance requirements without routine site visits.

• Artificial islands and cluster well pads – master‑local system reduces panel count; each well operates independently; fast expansion without replacing the entire system.

Product Types – Wellhead Operation Automation Configurations

1. Single‑Well Standalone WHCP (Basic Safety)

Best for: Remote exploration wells, small production wells, locations without communication infrastructure.

Includes: WHCP with RTU/PLC, pressure/temperature sensors, actuator (hydraulic/pneumatic/electric/solar), fusible plug loop, battery backup. Local ESD and manual control. Data logging (USB export). Communication ports are fitted for easy future upgrade to remote monitoring.

2. Single‑Well WHCP with Remote Monitoring (SCADA Ready)

Best for: Wells where production data needs to be viewed from a central office, but remote control is not yet required.

Includes: All standard WHCP specifications, plus cellular (4G/5G) or satellite communication interface, SCADA viewer dashboard (real‑time pressures, temperatures, valve status, email/text alarm notifications, historical trend charts). View‑only mode – remote control not enabled. Easy software upgrade to full control.

3. Single‑Well WHCP with Full Remote Operation & Control

Best for: Wells where remote shutdown, valve operation and setpoint adjustments are required from a central control room.

Includes: All standard WHCP specifications, plus secure remote access (VPN), full two‑way control capability, authorised remote valve operation (SSV, wing valves, choke valve), remote setpoint changes for pressure/temperature thresholds, user authentication and audit logging.

4. Multi‑Well Master‑Local WHCP System (Cluster Pad)

Best for: Multi‑well pads (shale gas pads, cluster oil wells, offshore platforms, artificial islands). A single master panel controls up to 24 wells.

Includes: Master panel in central equipment building, remote I/O termination boxes at each wellhead via hardened digital links (Ethernet, fiber optic or RS‑485), one operator interface controlling all wells, modular design – each well functions independently; maintenance on one well does not affect others.

5. Full‑Field SCADA System with Distributed WHCPs

Best for: Oil and gas fields with dozens or hundreds of wells scattered over wide geographic areas.

Includes: Each wellhead equipped with a smart WHCP that operates autonomously when communication is lost. All WHCPs report to a central SCADA server (on‑premises or cloud) via cellular, satellite, radio or fiber. Unified field view with real‑time data, alarm management, reporting, historical trending and remote well control from a single workstation.

6. Offshore / HPHT Wellhead Automation System

Best for: Offshore platforms, deep gas wells, HPHT fields requiring remote ESD and SIL‑rated safety logic.

Includes: API 6A pressure‑class components, sensors rated up to 250°F, explosion‑proof hazardous area enclosure (Zone 1/2), dual power supplies, dual communication paths, triple‑redundant safety logic (SIL‑3 option), corrosion‑protected marine finish, DNV/ABS certification available, sub‑second ESD response time.

7. Arctic‑Rated Wellhead Automation System (Cold Climate)

Best for: Siberia, Northern Canada, Alaska and other regions with sustained sub‑freezing temperatures.

Includes: Extended operating temperature range to -45°C, heated enclosures (electric heat tracing), low‑temperature hydraulic fluids and seals (pour point below -55°C), battery heaters with oversized battery banks, insulated wiring and weather‑proofed connectors, nitrogen‑purged instrument enclosures for freeze‑thaw cycles. Proven in Russia.

8. Solar‑Powered Wellhead Automation System (Off‑Grid)

Best for: Remote wells without utility grid access, unmanned locations, low‑carbon footprint operations.

Includes: Low‑power components (<50 W typical consumption), solar array sized for local insolation, deep‑cycle battery bank with 5–10 days autonomy, charge controller with under‑voltage and over‑voltage protection, optional cellular or satellite communication, full ESD and data logging functionality – same API 6A certified safety features as grid‑powered systems.

Why Choose SJ Petro for Wellhead Operation Automation?

Because wellhead automation is not an off‑the‑shelf product. It is an engineered system that must work in your specific wells, with your specific crew, on your specific timeline. You need a manufacturer who designs, builds, certifies and supports every component.

Your Challenge	SJ Petro’s Answer
"I need API certification for an international tender.”	Full API 6A, 14A, 14B, 14C compliance. API monogram available. Complete certification packages – MTRs, hydrostatic certificates, NDT reports, API data sheets.
"I have 24 wells on a pad and want one control room.”	Master‑local system. One master panel controls up to 24 wells, remote I/O boxes at each well. Each well operates independently – maintenance on one does not affect others.
"My wells are scattered with no grid power and no cellular signal.”	Solar‑powered WHCP + satellite communication. 5–10 days battery autonomy, low‑power design (<50 W). Deployed in remote deserts and jungles.
"I need to integrate with my existing Emerson SCADA.”	We support Modbus TCP/IP, OPC UA, DNP3, MQTT. Our engineers work with your IT/OT team to ensure seamless integration.
*"I operate in -45°C winters. Standard equipment freezes.”*	Arctic package – heated enclosures, low‑temp hydraulics (pour point below -55°C), battery heaters, insulated wiring. Proven in Russia.
"I need a SIL‑2 rated ESD for my offshore platform.”	IEC 61508/61511 certified SIL‑2 (or SIL‑3) rated logic solvers, sensors and actuators. Full SIL assessment documentation and third‑party certification available.

More reasons to trust SJ Petro:

• Sinopec Group heritage – 80+ years of oilfield equipment engineering, founded in 1941

• API 6A, API Q1, ISO 9001 certified – full international certification, not "designed to” claims

• In‑house manufacturing – we design, fabricate and test our own WHCPs, RTU/PLC systems and API‑certified wellhead components

• Global track record – wellhead operation automation systems delivered to Central Asia, Russia, Middle East, South America, Africa and Southeast Asia

• Global market growth – the wellhead control system market was valued at USD 1.08 billion in 2025 and is projected to grow to USD 2.25 billion by 2032 (CAGR 10.97%)

• Flexible commercial terms – milestone payments (30/40/30), operating leases and direct financing available for qualified buyers

Frequently Asked Questions (FAQ) – Wellhead Operation Automation

Q1: What is wellhead operation automation?

A: Wellhead operation automation is an integrated system that controls, monitors and safeguards a well. It consists of a wellhead control panel (WHCP) with a PLC or RTU, sensors and actuators, and optional SCADA remote monitoring software. The WHCP continuously measures parameters such as pressure, temperature and flow, automatically shuts in the well if setpoint limits are exceeded, and reports real‑time data and alarms to a central control room.

Q2: What is a wellhead control panel (WHCP)?

A: A WHCP is the local hardware unit installed near the well. It houses the control logic processor (PLC or RTU), power supplies, operator interface, emergency shutdown (ESD) buttons and valve control solenoids. It serves as the "brain” of the wellhead automation system, executing safety shutdown logic and communicating with remote SCADA servers.

Q3: What is the difference between ESD, PSD and basic wellhead shutdown?

A: ESD (Emergency Shutdown) is the highest‑priority safety function, triggered by well‑level conditions such as high/low pressure, high temperature, fire detection or manual ESD pushbutton. It shuts down the entire well. PSD (Process Shutdown) is triggered by facility‑level conditions, such as separator high level or flare flame failure. Basic wellhead shutdown refers to routine valve closure for maintenance or workover. Our automation system includes all three types with clear prioritisation.

Q4: What API standards govern wellhead operation automation?

A: API Spec 6A (21st Edition) governs the wellhead valves, chokes, flanges, Christmas trees and other pressure‑containing components. API Spec 14A and API RP 14B cover downhole safety valves and subsurface safety valve systems. API RP 14C provides the framework for safety analysis, design and testing of offshore production platform safety systems. Our system is fully compliant with these standards.

Q5: What is SIL rating, and why does it matter for wellhead control?

A: SIL (Safety Integrity Level) is defined by IEC 61508 and IEC 61511 standards. SIL‑2 provides moderate protection; SIL‑3 provides high‑confidence safety for applications where the risk of failure must be extremely low. For wellhead ESD, SIL‑2 or SIL‑3 rated components ensure that the safety function will perform reliably even when a fault occurs. Our WHCP can be specified with SIL‑rated logic solvers and sensors.

Q6: Can the WHCP be retrofitted to an existing well?

A: Yes. Our WHCPs are designed for retrofit applications. We can interface with existing API‑flanged valves and add actuator kits (hydraulic, pneumatic or electric) to automate manual valves. The existing wellhead does not need to be replaced.

Q7: What communication options are available for remote monitoring?

A: We support Modbus RTU (RS‑232/RS‑485), Modbus TCP/IP, DNP3, IEC 60870‑5‑104, OPC UA and MQTT for integration with SCADA hosts. Physical communication can be via 4G/5G cellular, satellite (Iridium, Inmarsat), fiber optic, licensed or unlicensed radio, or direct Ethernet.

Q8: Is the WHCP powered by grid electricity or solar?

A: We provide WHCPs for both. For grid‑powered locations, we use 110/220 VAC with battery backup (8+ hours). For off‑grid sites, we can supply a solar‑charging battery system sized for the well’s power requirements, with enough battery capacity for 5–10 days of autonomous operation during poor solar conditions.

Q9: What is the expected lifespan of a wellhead automation system?

A: With proper maintenance (periodic battery replacement, actuator service, software updates), our system is designed for a 10‑ to 15‑year operational life. Many of our API 6A wellhead components have field life exceeding 20 years.