Company confidential, do not distribute
Well site facilities Onshore Conference
Sept. 2018
Ken Goh, Senior Project Engineer
Sylvain Levac, Corporate Sales Executive
Adjustable choke design to handle erosion
masterflo.com
The leader in choke technology
Copyright 2011 © Master Flo
An evolving industry
Ever more demanding production processes
100 years + of production process evolution SAGD / Cyclic Steam
Far from Titusville in 1859 the last 25 years of production evolution brought us…
– Shale oil & gas production
– SAGD Process
– Cyclic steam process
– More aggressive “Well management programs”
Unconventiona O&Gl
– Increasing sand volume being used
– Resisting temptation to reduce flow back time
– More demanding well stimulation techniques
Today’s producer have to handle more aggressive process conditions.
–Sand and organic erosion (up to 15%)
–High temperature (700F+)
–Higher pressure (15K and 20K)
• Creating Initial higher pressure delta with often supersonic speed conditions 15% sand and organics
from SAGD production
–High flow rates over a wide range of pressure conditions true well life.
• Maintaining flow rate with a delta reducing by over 3000psi over well depletion cycle.
–Hydrate formation, that’s always fun…
–And yes.. Sand.. Did we say sand?
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Evolving demands
Demanding production processes
Sand is proving to be the new enemy …
• Coated, man made or natural, It’s all the same.. Evil.
• A common denominator for all unconventional O&G production, sand erosion is costly in multiple ways;
•Down time
•Lost of production
•Difficult implementation of the well management program
•High parts and maintenance cost
• High cost of ownership
While operation wants more from the choke..
• Controllability
• Repeatability
• Reliability
• Long life trim
• Long term shut off capabilities
• Increase up-time
• Low cost of ownership
Fact: Your production choke valves are your primary control elements, and a
major determinant in your ability to achieve profitability.
• Every production choke designs has merits,
• But they also have limitations when faced with sand…lets review…
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Needle and Seat Choke (Circa 1925)
Flow
Results of sand erosion
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M.O.V Wafer Choke (Circa 1950)
Hydrate
Flow
Results of sand erosion Results of sand erosion Results of sand erosion
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M.O.V Choke (Circa 1950)
Flow
Results of sand erosion
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Plug and Cage Choke (Circa 1975)
Flow
Results of sand erosion
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External sleeve design (evolving since 2000)
Flow
Advance technology
Evolved trim designs
Results of sand erosion
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Erosion Performance Comparison:
Adjustable Chokes
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Design Criteria: Driving Factors
The science behind the design
• Pressure – API 6A Energy Distortion & ASME Methods, Material Mechanical Properties.
• Temperature – API 6A Temp Class, Annex G Derating, Material Mechanical Properties, etc
• Corrosion – Sweet and Sour, NACE MR0175
• Erosion – Velocity, Energy, Material
• Flowrates – Adjustability, Flow Coefficient (Cv), Choked flow, etc
• Controllability – Cv curve, Adjustment Resolution, etc
• Cavitation – Fl factor
• Hydrate Formation – Xt factor
• Automation – Safety, Monitor, Labor, $$$
• Cost – Cost of Ownership
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Continuity Equation: (V-A) The science behind the design
• Conservation of Mass:
ṁ1 = ṁ2
ρ1 V1 A1 = ρ2 V2 A2
V1 A1 = V2 A2 Incompressible Fluid
V1 A2 A1 > A2 ; V1 < V2
V2 A1
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Bernoulli’s Principle: Venturi Effect (P-V) The science behind the design
• Conservation of Energy: Kinetic Potential
V P V P
P1 > P2 V1 < V2
ΔP = Pin - Pout
Pin Pout
Vena Contracta
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Gay-Lussac’s Law: Joule-Thomson Effects (P-T)
The science behind the design
• Conservation of Energy: Internal Potential
T1 < T2 ; P1 < P2
• The act of reducing the pressure of gas flow through a restrictor results in a phenomenon known as the Joule-Thomson Effect.
• Cooling occurs because work must be done to overcome the long-range attraction between the gas molecules as the move farther
apart during the expansion process.
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Erosion Control
Trim Life Prediction Model
• Erosion = Function (Fluid Kinetic Energy, Subject Material)
– Fluid Kinetic Energy: Ek = ½ mV2
– Subject Material: Primary & Secondary Wear Areas
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Erosion Control
The science behind the design
Erosion Management
– Energy Management
• Impingement – Energy dissipation
– Velocity Management
• Valve Internal Design – Slower is better
– Material Management
• Hardness + Corrosion resistance
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Velocity Control
The science behind the design
B Body Velocity C Orifice Velocity
Velocity must be acceptable for alloy or
stainless steel material. Tungsten Carbide Trim allows
Typical hardness Rc 22 Fluid energy absorbed high acceptable velocity.
Typical hardness RA 94
INLET
D Trim Exit Velocity A Inlet Velocity
Inlet velocity must be acceptable for
Velocity must be acceptable for
alloy or stainless steel material.
alloy or stainless steel material.
Typical hardness Rc 22
Typical hardness Rc 22
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OUTLET
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Erosion management The science behind the design
Upstream Vena Contracta Downstream
• Larger Choke Size - Larger Cage ID
• Longer Deadband • Proper sized ports (Minimum Perimeter)
• Larger Body Outlet Bore or End
• Larger Choke Size • 2 or 4 ports Connection
• Larger Body Inlet Bore or End • Harder Materials (>Ra 94 5CB TC) • Body Outlet TC Wear Sleeve
Connection
• HES Choke
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Velocity Control External Sleeve and cage
Aerodynamics/Hydrodynamics
Empirical data demonstrates that fluid impingement will effectively dissipate 25% or more of the energy.
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Trim Design
Design evolution
Trim Dead band
Trim Dead Band
❑ Protects seat surface from high velocity fluid associated with trim ports
❑ Increases body annulus area for reduced velocity
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Trim Design
Design evolution
Retaining Sleeve
Retaining Sleeve
❑ Protects body from fluid velocity and potential erosion
❑ Eliminates the need for wetted body threads
❑ Facilitates ease of service with no special tooling.
❑ Allows self-aligning trim components
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Trim Design
Design evolution
Deflection Lip
Throttling edge
Shut-off protection
❖ Deflection lip on collar separates
throttling surface from seating
surface for prolonged shut-off
Seating ❖ Metal to Metal seat surfaces provide
Surfaces extended Class 5 shut-off
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Material & Design Advancements
Material evolution
Tungsten Carbide
• To be able to contain the energy and provide
suitable erosion resistance tungsten carbide is
used for the trim components
• Hardness being the feature of
interest, it should be known that not
all carbide grade are equal.
• Carbide grade should be manufactured from
binder consisting of Cobalt, Nickel, and
Chromium.
Solid Tungsten Carbide Cage
Solid Tungsten Carbide Insert
For Seat and External Sleeve
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Trim Material – Erosion
Material evolution
Corrosion Testing
TOUGHNESS CHART
10.18
5CB
MATERIAL
9.91
6% Ni
9.27
DC05
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9.2 Technology
9.4 9.6 9.8 10 10.2
K1C (MPa*m^0.5)
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Erosion Calculation: Trim Life Prediction
Max. (Worst) Case Scenario
• Max. Pressure/Pressure Drop
• Max. Temp
• Max. Oil Flow Rate
• Max. Gas Flow Rate
• Max. Velocity
• Min. Trim Life
Where sand depletion over time will increase life cycle exponentially..
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FL or Xt (Pressure Recovery) Factor
Material evolution
• Provides a correlation between 1.0
Master Flo cage/ext. sleeve
pressure drop and lowest pressure
point in the valve (PVC)
0.90
• Lower PVC means lower temperature
Needle & Seat
0.80
0.70
0.60
P1 – P2 i.e. the higher FL number, the
FL2 = lower the risk of cavitation
P1 – PVC 0.50
0 10 20 30 40 50 60 70 80 90 100
% open
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Hydrate formation External Sleeve and cage
Aerodynamics/Hydrodynamics
In order to best mitigate hydrate formation and cavitation, the “vena contracta” and recovery factor
information is crucial and more predictable.
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Choke Trim Designs For Different Applications
Standard 4-port Custom Multi-port
• General Purpose • Reduction In Noise
• Excellent For Erosion Control • Improved Controllability On Startup
• Good Controllability • Available In SS Or Tungsten Carbide
• Available In SS, Stellite Or Tungsten Carbide
2-stage Labflo
• Available In Standard And High Pressure Drop • Excellent For Noise Control
• Good For Cavitation Control • Excellent For Cavitation
• Good For Noise Control • Liquid, Gas And Multi-phase Applications
• Available In Stellite Or Tungsten Carbide • 3 Distinct Pressure Drop Configurations along Travel
• Available In Tungsten Carbide
Laminate 4-port
• Used In High Impact Applications To Reduce Catastrophic Well Cleanup
Failure (Tested To Withstand • Used In High Impact Applications To Eliminate Catastrophic Failure
300 J Energy) • Absorbs Impact Energy In The Stainless Steel Outer Cage
• Absorbs Impact Energy In Outer Cage; Soft Core Between • Recommended For Flowback And Well Cleanup Operations
Cages Acts As A Crack Arrester • Proprietary 5CB Tungsten Carbide On All Erosion Sensitive Areas
• Continuous Bond Technology Maintains Structural Integrity
• Available In Tungsten Carbide
Conclusion
Trim design comparison
POS MOV N&S P&C C&S
Adjustable No Yes Yes Yes Yes
Shut Off Capability No Yes Yes Yes Yes
Jet Impingement No No No Yes Yes
Energy Dissipation
Throttling = Sealing surface Yes No Yes Yes No
Hi-speed Jet into Body Outlet Yes Yes Yes Yes No
Fl and/or Xt Factor Lo Lo Lo Med Hi
Torque/Thrust Requirements N/A Hi Lo Lo Lo
Rotating Stem (Stem Seal) N/A Yes Yes No No
Custom Trim No Kinda No Yes Yes
Control Resolution No Bad Bad Good Good
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Conclusion
• Process conditions are getting more demanding.
– More sand downhole during frac
– Higher flow rates
– Increase emphasis on controllability and repeatability to meet well
program demands.
– Cost containment against sand erosion effects taking a front seat.
• Advance trim design and materials advantages…
– With it’s ability to control velocity at the trim, the external sleeve
design provides;
• Long trim life
• Lowest cost of ownership
• Increase Up-time
• Improved controllability and repeatability
• Long term shut off capability
• Proving itself to be best defense against the effects of sand erosion.
End.
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