Field Trial Summary:  Impact of CORTEC Automated Production Chokes in Oil and Gas Operations

Field Trial Summary:  Impact of CORTEC Automated Production Chokes in Oil and Gas Operations located in the West, Central, and South Texas Regions

Problem

The primary challenge facing this CORTEC client pertains to the inefficiencies encountered in three operational oilfield areas across Texas. These inefficiencies encompass reduced oil production, increased labor demands—particularly concerning non-productive time—suboptimal or malfunctioning equipment, and elevated periods of downtime.

 

Overview

The following information was presented to CORTEC by an active production choke end user. It represents their statistical analysis and procurement conclusion based on the details within this summary.

The client determined that the use of automated chokes would help improve upon these issues and selected four separate choke manufacturers to provide equipment for head-to-head evaluation within the same well pads. This method presented the most practical means of replicating operating conditions between choke brands as closely as feasible. CORTEC supplied eight choke assemblies, which were electrically actuated to 10,000 PSI and had both 2” and 1” orifice trim configurations.

This field trial, conducted over a one-year period beginning in 2022, shows the transformative impact experienced by the client following the implementation of automated CORTEC production chokes and remote monitoring technologies into their operations across the West, Central, and South Texas regions. The data demonstrates that these technological advancements have significantly improved operational efficiency, reduced labor requirements, and enhanced equipment reliability, thereby optimizing overall production.

 

 

Automation Implementation West and South Texas

Key Benefits of Automation

    • Remote Operation

The introduction of remote monitoring and control eliminated the need for personnel to make adjustments onsite, significantly lowering labor costs and enhancing response times.

    • Enhanced Efficiency

Automated chokes enabled real-time adjustments to flow rates, ensuring optimal production levels across wells. This capacity prevented pipeline shutdowns caused by pressure fluctuations, thereby maximizing uptime.

    • Improved Equipment Reliability

The superior design and durability of CORTEC chokes resulted in significantly fewer maintenance hours, reducing operational disruptions and long-term costs.

    • Safety and Environmental Benefits

A reduction in onsite labor mitigated the risks associated with hazardous conditions in the field. Automated systems facilitated precise control of production rates, decreasing the likelihood of spills and environmental incidents.

 

Results Achieved

    • Increased Oil Production and Reduced Labor Requirements

Following the transition to automated production chokes, the client experienced a 60% increase in oil production alongside a 40% reduction in labor hours. The ability to monitor and adjust production remotely allowed for more efficient resource allocation.

    • Reduction in Non-Productive Time (NPT)

Automated wells demonstrated a remarkable 50% reduction in NPT compared to manually operated wells. This was mainly attributed to the precision and responsiveness of the automated systems in mitigating operational disruptions.

    • CORTEC Choke Performance

Over a 12-month evaluation period, CORTEC Chokes consistently outperformed competitor equipment. Despite a slightly higher initial investment, the benefits associated with reduced maintenance requirements and superior reliability made CORTEC the most efficient product choice in performance metrics long term:

      • Maintenance hours:  25-40% less than competitors.
      • Replacement parts cost:  50-75% less than competitors.
      • NPT due to defects:  40-50% less than competitors.

 

CORTEC Chokes in the field

 

 

Operation-Wide Success

The West Texas operations have fully transitioned to automated production chokes for all wells, realizing tremendous success. Building upon these achievements, the South Texas operation has also embraced full automation across its wells, acknowledging its substantial positive impact on operational efficiency and production management.

 

 

 

Central Texas Automation Trial

The client conducted a trial to evaluate the efficiency of automated chokes vs manual chokes on similar producing wells.

Methodology:

      • One well was equipped with an automated choke, while another well with similar production characteristics was fitted with a manual choke.
      • Key metrics, including labor hours, production consistency, and NPT, were monitored over a six-month period.

Results:

      • The automated choke reduced man hours by 75% compared to the manual choke.
      • Real-time adjustments ensured consistent production rates, avoiding shutdowns due to pipeline pressure fluctuations.
      • The automated system resulted in a 50% reduction in NPT.

Conclusion: The trial demonstrated the efficiency and effectiveness of automated chokes, validating the need for broader adoption across the client’s operations.

 

 

Comparative Advantage of Cortec Chokes

The evaluation of choke performance revealed CORTEC as the superior choice.

Key findings include:

    • Maintenance hours reduced by 25-40%, allowing for greater resource allocation to other operational priorities. 
    • Replacement parts cost lowered by 50-75%, minimizing operational expenditures.
    • NPT due to defects reduced by 40-50%, ensuring greater operational uptime.

Recommendations by the client:

    • Standardize the use of CORTEC chokes to reduce maintenance costs and enhance reliability.
    • Expand the implementation of automated chokes across all operations to capitalize on labor savings and efficiency gains.
    • Continue leveraging real-time data and remote monitoring technologies to optimize production and reduce NPT.

 

Conclusion

Upon completion of the evaluation period, CORTEC chokes* were selected as the preferred solution based on superior performance, reduced operational costs, and exceptional client support compared to competitive options. Implementing CORTEC automated production chokes significantly transformed the client’s operations in these Texas regions. The technological advancements led to substantial improvements in oil production, labor efficiency, and equipment reliability, ultimately optimizing overall production outcomes and solidifying CORTEC’s reputation as a reliable partner in oilfield operations.

 

 

 

 

 

 

*CORTEC Production Chokes Tested:CORTEC Production Choke

  • West Texas:
    • CORTEC Model CC2: 2 1/16″ 10k, and 2 9/16″ 10k, 2″ Cage Style with Rotork actuator
  • South Texas
    • CORTEC Models NH1 and CC2:  2 1/16” 10k, 1” Needle and 1” Cage with Bettis 510 actuator
  • Central Texas
    • CORTEC Model NH1: 2 1/16” 10k, 1” Needle and 1” Cage

Learn more about CORTEC Production Chokes here.