Geothermal
API 6A Wellhead Equipment for Safe Well Completion
Designed according to project-specific requirements and for maximum flow rates and temperatures, our geothermal wellheads offer maximum operational safety and system availability. The use of metal-to-metal sealing ball valves on the wellheads ensures maximum reliability, long service life, and low maintenance requirements.
Since the first pioneering projects in 1978, we have equipped more than 45 projects under a wide range of geothermal conditions—including projects for lithium extraction.
For Smooth Operations
Support in All Project Phases
We support our customers in all project phases—from engineering through in-house manufacturing, installation, maintenance (e.g., pump replacement) to modernization of existing systems. Our custom-designed API wellheads meet the highest standards in safety, quality, and durability: manufactured from high-quality materials, equipped with gas-tight, metal-to-metal sealing ball valves.
Engineering includes project-specific design, 3D drawings, FEM analyses, approval documentation, and complete traceability of all components.
ENGINEERING
Project-specific design in close collaboration with the engineering partner
MANUFACTURING
From machining of raw materials to final assembly, all production steps are performed in-house
INSTALLATION
On-site, our service team supports the installation of wellheads and rental equipment
MAINTENANCE
24/7 operational support, spare parts, and regular inspections
Custom Design Highlights
Our Wellhead Designs
for Deep Geothermal
Our custom API wellheads meet the highest standards in safety, quality, and durability. They offer flexible ESP and LSP designs, interchangeable solutions for production and injection, as well as the integration of multiple components in compact assemblies with reduced flange connections. This is complemented by control and injection lines, horizontal or vertical ESP plug-in connections, additional connection options, and flexible fail-safe-close automation with electric, hydraulic, or pneumatic actuators.
Bypass
The design with large-volume thermal water bypass (according to API 6A) enables gentle pump start-up and shutdown
during maintenance or system downtime.
The design allows for subsequent automation.
Adapter Flange
Allows eccentric mounting of the hanger while maintaining the centric alignment of the assembly with bypass.
Pump Connector
Cable feedthrough for the ESP pump.
Annulus Connections
Enable pressure monitoring and access to the annuli for measurement and control equipment.
Annulus Connections
Enable pressure monitoring and access to the annuli for measurement and control equipment.
Annulus Connections
Enable pressure monitoring and access to the annuli for measurement and control equipment.
Bypass Design
- Integrated thermal water bypass for controlled flow management
- Fewer components & reduced height
- Cost-effective maintenance
- Fast pump replacement
- Modular design for ESP
Vertical ESP
Plug-In
- Eccentric ESP design for production
- Master valve with fail-safe-close actuator
Double Barrier
- Twin ball valves for enhanced safety
- Reduction of height and width
- Modular design for interchangeability between injection and production
Horizontal ESP Plug-In
- Fewer components & reduced height
- Cost-effective maintenance
- Fast pump replacement
- Modular design for ESP
Custom Design
Individually Manufactured for Your Processes
Equipped with gas-tight, metal-to-metal sealing ball valves, they withstand high temperatures and pressures. Special designs offer additional safety and economic advantages.
Our low-maintenance and durable valves ensure maximum uptime in highly stressed systems.
Depending on the medium, the highest requirements for sealing technology, the material used, and the valve design are necessary: requirements that Hartmann products consistently meet.
Temperature
up to 500°C (932°F)
Pressure
up to 10,000 psi
Media
Hot water, steam, accompanying substances, abrasive and corrosive fluids, saline thermal waters
Applications
e.g., deep geothermal systems, production and injection wells, systems with ESP (Electric Submersible Pump) or LSP design, wells with high scaling tendencies, lithium extraction from thermal waters
Our Geothermal Reference Projects
Since the first pioneering projects, we have equipped approximately 45 geothermal projects with wellhead equipment. The map shows a selection of geothermal projects in which we are involved with our wellheads. You can request our complete reference list at marketing@hartmann-valves.com.
Reference
STADTWERKE MÜNCHEN
API 6A wellheads for extreme conditions ensure high tightness, long service life, and reliable shut-off.
- Equipment for various geothermal systems in the Bavarian Molasse Basin
- Support for existing systems through service
- Modernization of existing geothermal systems
Reference
GEOTHERMAL TRAUNREUT
API 6A wellheads for extreme conditions ensure high tightness, long service life, and reliable shut-off.
- District heating and geothermal power plant
- Complete service from a single source
- High-performance geothermal doublet (for up to 3000 PSI/207 bar)
Solutions for Extremely Hot Geothermal Wells & EGS Wells
Superhot & Supercritical Geothermal
Geothermal energy is a reliable source of renewable baseload energy. At the same time, next-generation developments—particularly superhot and supercritical systems—expose wellhead equipment to operating conditions that far exceed conventional standards.
Temperatures up to 500°C, aggressive geothermal fluids, mineral deposits (scaling), and repeated thermal cycles place extraordinary stress on valves and wellhead components. Under these conditions, conventional valve concepts often reach their functional limits.
Hartmann Valves develops API 6A ball valve solutions specifically designed for these extreme geothermal operating conditions. The focus is on ensuring operability, tightness, and long-term reliability—even under the most demanding conditions.
Engineering includes project-specific design, 3D drawings, FEM analyses, approval documentation, and complete traceability of all components.
For Smooth Operations
Challenges in Superhot Geothermal Applications
Superhot geothermal wells are characterized by a combination of high temperatures, chemically aggressive fluids, and pronounced scaling effects. Mineral deposits form within valves and adjacent components, while continuous thermal cycles lead to alternating mechanical stresses in the system.
These conditions directly affect valve performance, particularly in applications where reliable operation after shut-in phases is required. Components must remain functional even after prolonged exposure to high temperatures and deposits, placing increased demands on design and material selection.
Engineering includes project-specific design, 3D drawings, FEM analyses, approval documentation, and complete traceability of all components.
When Gate Valves Reach Their Limits
Why Ball Valves Offer Design Advantages in Superhot Geothermal
Superhot geothermal energy places the highest demands on valves. Mineral deposits, thermal stresses, and high differential pressures can impair the function of conventional gate valves. Ball valves follow a different design principle and thereby offer decisive advantages for operational safety and functionality.
Gate valves are widely used in wellhead systems. However, in superhot geothermal applications, their design principle reaches fundamental limits. High temperatures, aggressive fluids, and mineral deposits place considerable stress on the valve and directly affect function, tightness, and operability.
Particularly under these conditions, it becomes evident that gate valves are only suitable to a limited extent for extreme thermal and media-related requirements. As a result, the reliability of shut-off can decrease—a critical factor in sensitive geothermal applications.
At high temperatures, mineral deposits form inside the valve, particularly in seat pockets, cavities, and sealing areas. These deposits directly impair the sliding movement of the gate.
Over time, the gate can become stiff, block, or no longer open and close completely. At the same time, the operating torque increases significantly. In addition, thermal cycling accelerates wear on the sealing surfaces. This can lead to leakage, loss of sealing integrity, and limited or no longer reliably guaranteed shut-in capability.
Ball valves from Hartmann Valves are based on a fundamentally different design approach. Instead of a linearly moving gate, a rotating shut-off element in the form of a ball is used, which rotates within its own volume.
This eliminates many geometries and dead spaces where deposits typically accumulate and impair valve function. The movement is not sliding along critical internal surfaces, but rotating and structurally much less sensitive to scaling and deposit formation.
Due to the design principle, ball valves remain operational even in scaling environments where gate valves often reach their limits. The metal sealing system ensures reliable performance even at high temperatures and in aggressive geothermal fluids.
In addition, the design enables operation under full differential pressure. Robust actuation systems are capable of handling high torques and overcoming deposits in a controlled manner when necessary. This maintains valve function even under demanding operating conditions.
For operators, the use of ball valves means: greater operational safety, more reliable actuation, and long-term higher valve functionality in superhot geothermal applications. Ball valves from Hartmann Valves remain operational where conventional gate valves fail or operate only to a limited extent.
This reduces the risk of failures, improves reliability during shut-in phases, and supports stable system operation even under extreme thermal and mechanical stresses.
For Safe Operation
Design Advantages
The design of ball valves from Hartmann Valves is specifically engineered for geothermal applications at high temperatures. By avoiding cavities and dead spaces, scaling deposits are reduced and operability is ensured even in highly stressed environments. The The elastomer-free metal-to-metal sealing system ensures stable performance up to 500°C and resistance to aggressive media. Furthermore, the design accounts for temperature fluctuations and operation under full differential pressure as well as high torque requirements, ensuring reliable actuation even after long periods of use. A grease-free design concept additionally increases operational safety. Grease cannot be used, as it is washed out or thermally decomposed at these temperatures.
Installation, Operation, and Maintenance
Our experienced service personnel are always available to support you in geothermal projects: for extensive work such as the installation or modification of wellheads, the installation and removal of valves in systems, support during overhauls, or maintenance of our products.
- 24/7 technical support from our service team
- Rental Equipment
- Spare Parts and Repairs
Certified Safety for Deep Geothermal
Our high-performance valves meet national and international standards, including:
- API 6A, API 6D, API 7-1
- ISO 15848 (for fugitive emissions)
- ATEX (for explosive atmospheres)
- SIL
- TA-Luft
- Fire Safe
- NACE
Our Solutions for Geothermal
INDIVIDUAL DESIGN
Wellheads in individual design are custom-manufactured and designed for the highest requirements. The modular design enables precise configuration for the respective application.
BLOCK DESIGN
Wellheads in block design are custom-manufactured and designed for the highest requirements. The integrated block design reduces interfaces, simplifies assembly, and increases operational safety.
Contact Us
We support you in all project phases: from planning and design through manufacturing to installation and regular inspection.
FAQ
What challenges occur in geothermal and particularly superhot applications?
Our wellheads are specifically developed for geothermal applications. They offer maximum operational safety, even at high temperatures up to 400°C and pressures up to 10,000 psi. metal-to-metal sealing ball valves provide durable and low-maintenance sealing.
Why do gate valves reach their limits in geothermal applications?
Gate valves reach their limits in geothermal applications particularly due to high temperatures, aggressive fluids, and mineral deposits (scaling). Deposits accumulate in seat pockets, cavities, and sealing areas and can block the movement of the gate, increase the operating torque, and damage the sealing surfaces.
In combination with thermal cycles, this often leads to valves no longer being reliably operable after shut-in phases. Particularly in superhot geothermal applications, this poses a significant risk to operational safety, as a safe shut-off function is no longer guaranteed.
In which project phases does Hartmann Valves provide support?
From engineering through manufacturing, installation, rental equipment, and maintenance to modernization of existing systems—Hartmann Valves offers support in all project phases.
What requirements apply to valves in superhot geothermal?
Valves must withstand extreme conditions, including high temperatures, aggressive media, scaling, and repeated thermal cycles. At the same time, safe operation under full differential pressure and reliable function even after extended downtime periods are required.
This requires specially designed designs, elastomer-free sealing concepts, and highly resistant materials.
What special designs are possible?
In addition to standard designs, we offer custom solutions for ESP/LSP, internal bypasses, flushing connections, or automation systems with electric, hydraulic, or pneumatic actuation.