Engineer Leads Installation of his organization’s First High-Pressure Onshore Gas Wells

By Salami Adeyinka

The technical barriers surrounding high-pressure, high-temperature well production have long represented one of the oil and gas industry’s most formidable engineering challenges. Operating conditions of 10,000 psi and 100 degrees Celsius place extraordinary demands on materials, instrumentation, and control systems—demands that have historically limited onshore deployment of such demanding specifications.

Shuaibu Nuan has successfully managed the instrumentation, control, and automation works for what marks a significant milestone: the installation and production startup of the first high-pressure, high-temperature onshore gas wells in his organization’s Nigerian operations. The seven-well project has added 400 million standard cubic feet per day of natural gas production, effectively doubling the processing facility’s capacity.

The technical complexity of HP/HT wells extends far beyond conventional installations. Standard instrumentation connections and fittings simply cannot withstand the extreme pressures involved, requiring specialized solutions that balance safety requirements with operational functionality. Recognizing this challenge early in the project, Nuan proposed the adoption of special high-pressure autoclave connections and fittings for all instrument connections—a decision that proved critical to the project’s success.

“The margin for error in high-pressure instrumentation is essentially zero,” notes an industry technical specialist. “Every connection point represents a potential leak path under extreme conditions. The choice of connection technology isn’t just an engineering preference—it’s a fundamental safety consideration.”
The project required Nuan to coordinate the installation of multiple complex systems: wet gas meters for production measurement, wellhead control panels for operational management, instrument air compressors, integrated control and safeguarding systems, and corrosion injection packages. Each system needed to function reliably under conditions that would challenge conventional equipment ratings.

Site installation presented its own unique demands. Unlike offshore platforms where construction occurs in controlled fabrication yards, onshore installations must contend with variable field conditions, extended supply chains, and the integration of multiple vendor packages into a cohesive operational system. Managing these variables while maintaining the exacting standards required for HP/HT service demands both technical knowledge and practical problem-solving ability.

The control and safeguarding systems deserve particular attention. At 10,000 psi operating pressure, the consequences of control system failure or safety system malfunction are severe. The instrumentation and automation architecture must provide reliable process monitoring, responsive control, and fail-safe protection even under the extreme conditions these wells generate.

Beyond the technical achievements, the project’s impact on facility capacity cannot be overstated. Doubling natural gas production from a single project represents transformational change for the processing facility’s economics and the broader supply chain it serves. The additional 400 million standard cubic feet per day translates directly into enhanced revenue generation and improved resource utilization.

Nuan’s role extended throughout the project lifecycle, from initial engineering through construction supervision to commissioning support. This continuity ensured that design intent translated effectively into field installation, and that inevitable construction challenges received timely resolution grounded in engineering fundamentals.

The successful deployment establishes a technical precedent for future high-pressure developments. Having proven that onshore HP/HT wells can be safely and reliably installed, the organization now possesses both the technical confidence and operational experience to consider similar developments elsewhere in its portfolio. The knowledge gained—from material selection to installation procedures to commissioning protocols—provides a foundation for replication.

For the broader industry, the project demonstrates that technical barriers once considered prohibitive can be overcome through rigorous engineering, appropriate technology selection, and disciplined execution. As operators worldwide seek to access increasingly challenging reserves, the lessons from this deployment offer valuable guidance for managing similar technical demands.