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KOP Surface Products produces reliable and cost-effective equipment that delivers a better return on investment for users. We manufacture a complete range of products for both offshore and land-based surface production. Our proven designs are combined with an industry-leading manufacturing plant to deliver some of the finest quality products in the business.
Our conventional wellheads are designed for all drilling and completion applications. They feature field-proven internal “straight-bore” profiles for casing heads, casing spools and tubing spools for maximum flexibility and ease of use. A wide range of sizes and pressure ratings is available to allow the design of the right configuration for any application.
Our standard sizes are cost-effective, as well as being fast and simple to install with little or no special service requirements. All our wellhead products fully comply with API design and testing requirements and are suited to a variety of casing and tubing programs from 2,000 psi to 15,000 psi.
Both our Surface Metal Seal (SMS) and Surface Elastomer Seal (SES) Unitized wellhead systems are unique to KOP Surface Products. They can be used in either offshore platform or land-based applications.
The SMS system offers metal-to-metal sealing and is designed for pressures of up to 15,000 psi. These high load capacities are possible thanks to its use of a patented split ring that distributes the load directly into the wellhead housing and also seals it securely to resist all wellbore fluids and gasses. The SES system offers similar performance to the SMS but this more cost-effective option utilizes elastomeric sealing elements, as opposed to the metal-to-metal design of the SMS system.
Both systems have an efficient design that optimizes both height and material usage. This reduces the number of BOP connections required and saves valuable rig time by allowing BOP testing to be undertaken with bore protectors in place. In addition, tools to manage the running, retrieving and testing of the system are incorporated into the design, and these require little or no rotation. This both simplifies installation and extends the life of the equipment.
Our Splitter wellhead system has a multi-bore wellhead which allows the drilling of two or more wells from the same conductor. This delivers significant savings in offshore applications, by reducing the size and quantity of wellhead platforms that are required by 50 percent or more.
The patented Splitter system has a flexible design that can be configured to meet customer requirements in any number of situations. This includes for both new and existing slots, or for new or existing platforms. Similarly it is well-suited to minimum-concept platforms; multi-branch horizontal wells; or in environmentally sensitive areas.
Two of the field-proven Splitter wellhead models, the Lateral Slim Twin (LST) and the Ultra Slim Wellhead (USW), now have a combined population of over 3,000 installations worldwide.
Our gate valves are designed to deliver the highest levels of performance and durability. They also comply with all necessary requirements for use in any oil or gas field application, including:
They offer true metal-to-metal sealing and are designed for pressures from 2,000 psi to 15,000 psi and include forged bodies and bonnets. The high load taper roller bearings in their design reduces the torque required for opening and closing, easing the strain on the system.
Performance is key, so KOP Surface Products engineers its gate valves to exceed the requirements of API 6A PR2 Appendix F with a working range that covers temperatures from -20˚C to 350˚C. In addition, the vales are fire test qualified in line with the requirements of API 6FA. They are available in DD, EE, FF and HH trim materials.
KOP Surface Products introduced its trademark Shear-safe actuator in 2012. Its unique design incorporates a pivot arm transmission system that gives the valve greater resistance against breaking. It offers higher levels of safety, reliability and performance when compared with conventional coil spring designs.
The springs within the Shear-safe actuator are designed with redundancy in mind. So if one or two springs should set, or even crack, the actuator will continue to function with little or no reduction in performance level. This offers a significant safety advantage over conventional spring actuators, which have no redundancy built in.
Reliability is improved too, as the longevity and reliability of disc springs is markedly higher than that of coiled springs, which can be prone to fatigue caused by higher stress. In terms of performance, the Shear-safe actuator delivers a return spring force approximately three times stronger than that of a conventional coil spring. Shear-safe actuators are designed for operating control pressures of between 3,000 psi and 5,000 psi, and valve working pressures ranging from 5,000 psi to 10,000 psi.
Their design exceeds the requirements of API 6A PR2 Appendix F with temperature ratings from 0˚C to 300˚C. The Shear-safe actuators are available in the material classes AA-HH.
KOP Surface Products has a team of over 200 highly qualified service technicians, strategically placed at locations around the world. We offer a comprehensive installation service as well as 24/7 operational assistance on all our products. Our flexible and focused set-up allows us to mobilize at short notice and create scenario plans with clients to ensure processes are in place for any potential outcome.
Our installation program ensures that equipment is installed at the client’s site in the fastest, safest and most efficient way. Our industry-leading installation team has a strong track record of delivering exceptional HSE performance at project sites. The experienced and highly trained installation engineers at KOP Surface Products are equally at home in either oil or gas applications, and at onshore or offshore sites.
Our comprehensive installation service includes support for any workover operations; casing cutting services; and the provision of wellhead documentation for regulatory editing. All installation plans devised by KOP Surface Products are created in conjunction with the client to ensure operations proceed smoothly. The diverse experience of the company’s engineers combined with its long history in the industry and broad spread of previous installations means KOP Surface Products gives customers optimum peace of mind.
Offering fast service and maintenance to support its products is one of the most important factors in keeping KOP Surface Products at the forefront of the industry. Our team of highly-qualified and experienced engineers are focused on providing fast and efficient service to customers, to ensure that downtime in the field is kept to a minimum.
We offer specialized maintenance services for onshore and offshore fields, including scheduled programs for recertification and documentation for regulatory auditing. Lubricator services are also offered, for both back pressure valves and valve removal.
All service and maintenance plans from KOP Surface Products are aligned with client needs to ensure fast and smooth operations. The diverse experience of the company’s engineers combined with its long history in the industry and broad spread of previous installations means KOP Surface Products gives customers optimum peace of mind.
In addition to on-site training, we offer monthly training programs at our own Center of Excellence for training, or we can arrange tailored training programs to suit client needs. We also offer a Total Vendor Management program and the Preservation, Storage and Management of customer assets.
We offer a wide range of wellhead equipment in our Rental Tool Pool, giving clients the ability to find the right balance between capital expenditure and operating expenditure on their project site. Renting equipment is particularly beneficial to small or medium sized field development projects.
Equipment available in our Rental Tool Pool includes exploration systems and tools, lubricator packages for both back pressure valves and valve removal, and casing cutter packages ranging from 4.5 inch internal to 36 inch external. We also have cross-overs, test pumps and chart recorders available, as well as a full stock of spare parts to fit all equipment in the Rental Tool Pool.
The extensive range of equipment available in the Rental Tool Pool can also be modified as necessary, meaning KOP Surface Products can offer a system that meets just about any configuration needs. We are also constantly developing and expanding our Rental Tool Pool and can offer a Total Vendor Management program to support.
As the life of wellhead components often exceeds the life of wells themselves, refurbishment or repair of components can offer a significant boost to customers’ return on investment. By using refurbished equipment at new well sites, customers can dramatically reduce or even eliminate the need for additional equipment. The team at KOP Surface Products can offer full refurbishment and repair on all types of wellhead equipment and Christmas trees. What’s more the company backs the quality of its work by offering all refurbished equipment a full 12-month warranty.
A number of services are available. In addition to general refurbishment of customer wellheads and Christmas trees, KOP Surface Products also offers hydro and gas testing of valves, cross-overs and rises, and we can also facilitate the cutting and re-cutting of tubular threads, including bucking services. We will also refurbish equipment from other manufacturers or upgrade existing products with new componentry to improve performance.
Our global engineering and manufacturing support is headquartered at our central plant in Batam, Indonesia, while we have an ever-increasing number of satellite repair facilities and a strong spare parts inventory. The quality standards and processes in place at KOP Surface Products exceed industry standards and we work only with vendor partners who meet our strict quality and audit requirements. We also offer a Total Vendor Management program where applicable.