One Size Does NOT Fit All - CORTEC

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CORTEC’s Diverse Choke Line and Expertise Offer Precise Flow Control

In the oil and gas industry, where speed and cost-efficiency are paramount, OEMs strive for standardization through the use of commodity-manufactured valves. These products offer the availability and utility that end-users require to ensure smooth operations. However, the unique nature of choke valves makes them difficult to standardize under a “one size fits all” approach.

Choke valves regulate flow rate and reduce pressure to process produced fluids downstream. To achieve optimal performance, many variables must be considered in the choke selection process. The right type and size of choke not only improve performance but also extend the lifespan of both the choke and related equipment.

Choke Selection Criteria

• Working Pressure and Temperature
• Inlet/Outlet Connections: Type, Size, etc.
• Nominal Body Size
• Trim Type: Tapered Needle, Cage/Sleeve, Rotating Disc, Multi-Stage, Positive Bean, etc.
• Means of Operation: Manual or Remotely Actuated
• Service Conditions: Corrosive, Abrasive, Sour
• Flow Media: Oil, Gas, Water, Specific Gravity, etc.
• Flow Rates: Maximum, Minimum and Normal
• Design and Quality Specifications: API, ANSI, etc.

The combination of these factors, along with variations in choke models from different manufacturers over the years, makes the idea of a universal solution impractical. Expertise in the design, manufacturing, and performance of choke valves is essential to meet the operational needs of clients effectively.

CORTEC has established itself as a leader in choke technology with a comprehensive knowledge base and diverse range of models for various applications. From wellhead production to extreme service operations, CORTEC’s field-proven solutions cater to almost any requirement. Choosing the right solution is crucial to avoiding costly downtime. Consistent, quality manufacturing, precise tolerances, top-grade materials, and adherence to stringent industry standards are of utmost importance.

Why does each choke application need to be evaluated independently?

Determining the right choke size and model is essential for operational success. Many choke-related issues stem from improper selection of orifice size or trim style, leading to severe conditions like erosion, noise, and cavitation. These issues can cause equipment damage or expose processing fluids and pressures to the atmosphere, endangering personnel, the environment, and operational surroundings. CORTEC's engineering team, equipped with field experience and analytical tools, helps end-users avoid such mistakes.

Examples of Improper Model Selection

Scenario 1. Location: Colombia

Images below show another OEM choke operating with a 2” needle trim at a 36/64” orifice setting, approximately 5% open. The choke was vibrating itself closed due to the trim barely being cracked. CORTEC’s sizing software recommended a ¾” needle trim, which was accepted by the client to operate the choke within an optimal flow capacity range. CORTEC generally selects chokes to operate between 20-80% of valve travel, with a maximum range recommendation of 10-85%.

Scenario 2. Location: Mexico

A choke with 4” trim on a manifold broke due to being significantly oversized for the application. CORTEC’s evaluation found the choke was operating at 5-8% open, causing excessive vibration. The optimal trim size was between 1.5” to 2”. CORTEC worked with the client to replace the oversized choke, avoiding future premature trim failure.

Scenario 3. Location: Pakistan

A customer purchased a choke assembly with an alloy steel body and bonnet. The choke leaked from the flange seal areas due to high CO2 levels (8%), causing accelerated pitting in the alloy steel. CORTEC recommended using corrosion-resistant materials, which increased service life and reduced operational costs for the client.

How should I evaluate choke performance over the life of an operation?

Equipment adaptation throughout a well's life is crucial. As a well depletes, flow rates and pressures change, necessitating modifications to the choke configuration. These changes may include altering trim size or type and actuation methods. CORTEC helps clients implement higher levels of automation, allowing more wells to be operated remotely. Such upgrades often involve simply swapping the bonnet assembly, enhancing efficiency and reducing costs.

Are you interested in learning more about wellhead choke valve? Contact us today to secure an expert consultation!

One type of choke body can be adapted into several variations of models in trim type, size, and actuation method.

Examples of in the Field Equipment Adaptation

Scenario 1. Location: West Texas

Shown here is a sampling of 53 manual choke assemblies converted to electric actuation to streamline production for an operator. This conversion from manual to electronic, remotely operable design allows for fewer personnel and real-time assessment to manage flow rates, thus reducing OPEX and increasing profits.

Scenario 2. Location: Middle East

CORTEC was approached by a client to evaluate flow conditions for higher production rates. CORTEC’s sizing software determined that replacing the existing 1” max orifice needle trim chokes with 2” max orifice external cage types would boost production. CORTEC worked with the client to replace 190 chokes and provided a delivery schedule and training plan to meet their operational needs.

Extreme Service Chokes

CORTEC offers a line of extreme service chokes designed for highly erosive drilling and well servicing operations. These robust designs incorporate field-friendly maintenance features, such as dual-sided trim for increased life usage, gantry systems for removing bonnet assemblies with chokes installed, and specialized service tools to enhance the end-user experience.

Choke gantry shown being used to expose internals. This is a highly resourceful tool for operations where trim changes are anticipated to be more frequent.

Extreme Service Choke Design Considerations

While choke and trim orifice sizing remain crucial, extreme service chokes emphasize the overall operational design. Applications range from simple pressure bleed-off to precise flow rate and pressure control. Flow conditions and usage durations heavily influence maintenance requirements and component change-out frequencies. Understanding manifold piping system design is key to long-term success. Whether managing a 1.5” orifice hydraulic piston choke for high-pressure vessel bleed-off or a 6” orifice electric motor-driven choke for high flow rate MPD systems, CORTEC’s expertise ensures optimal selection.

Conclusion

The world of choke design is diverse and constantly evolving. Users may become frustrated when simple solutions are not achievable, as commercial and commodity-driven selections are not suitable for all situations. Many manufacturers lack the specialized focus to support their clients adequately. CORTEC, as a dedicated choke-focused manufacturer, offers extensive options and resources built within U.S. facilities, adhering to API specifications 6A and 16C for choke manufacture.

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