Extending Choke Valve Life With SlurryFlo Backpressure Control

BACKPRESSURE CONTROL WITH SLURRYFLO CONTROL VALVES

When operating multi-well gas pads in abrasive, high-sand environments, erosion is a constant threat, particularly for choke valves under high pressure. A leading Canadian gas and NGL producer faced exactly this issue at their well pads.

Each pad hosted approximately 10 wells, all equipped with 2500# surface choke valves. That’s 10 choke valves per pad, all exposed to high-velocity flow (often exceeding 60 feet per second), and the erosive impact of sand-laden gas. Valves were wearing out in just a few weeks. That created a serious challenge in terms of maintenance costs, safety, and downtime.

The Challenge

To combat rapid choke valve erosion, the operator tried a common workaround: installing a fixed orifice plate at the downstream end of the well pad header to induce backpressure. By increasing pressure in the gathering lines, velocity through the choke valves dropped, which significantly extended valve life.

But this workaround came with a trade-off. As the well’s sand production tapered off during flowback, the fixed orifice plate remained in place, restricting overall throughput and limiting production capacity.

The operator needed a more intelligent, adaptable solution; something capable of applying backpressure when necessary and opening up to allow high flow rates when conditions improve.

The Solution: SlurryFlo Control Valves

Working with SAF engineers through our local partner, Summit Valve & Controls, the operator sought a more effective approach. They needed a solution that could create backpressure during the early stages of production to protect the surface choke valves, while also allowing high flow capacity as conditions changed and production ramped up across the pad.

After reviewing process data, SAF recommended the SlurryFlo control valve, a proven performer in abrasive, high-solids environments. Thanks to its robust ASME 600 design and custom-engineered internal trim, the SlurryFlo valve offered the best of both worlds: erosion resistance and flexible flow control.

Implementation

SAF designed and delivered custom-trimmed SlurryFlo control valves (sizes 8" and 12", ASME 600) to replace the static orifice plates on the downstream outlets of the well pads. These valves were installed in the gathering lines and commissioned during the initial production phase, when sand concentration was at its peak and valve erosion was most aggressive.

Condition 1: Initial Operation Low pressure 1 well flowing
Condition 2: Initial Operation Low pressure 8 wells flowing
Condition 3: Initial Operation High pressure 1 well flowing
Condition 4: Initial Operation High pressure 8 wells flowing

100% Open

15% Open

The Result

The SlurryFlo valve created the necessary backpressure on the gathering system. As a result, velocity through the upstream choke valves dropped significantly, extending their operational life.

As sand content decreased over time, operators simply adjusted the SlurryFlo valve to reduce backpressure and allow more flow. Once the pad reached steady-state production, the same valve was relocated to the next well pad, repeating the process and maximizing asset value.

Even in the harshest early production conditions, the SlurryFlo valves achieved more than three years of continuous service between trim changes. That’s a significant improvement from the previous valve lifespan of just a few weeks.

What started as a challenge against sand erosion became an opportunity for efficient, high-performance well pad operation. With the right solution, the customer found a long-term, repeatable solution that protects equipment, boosts production, and makes life easier for their operations team.

The SlurryFlo Control Valve provides several critical advantages in this application:

Valve trim lifespan extended to 3+ years.

No performance degradation, even in sand-heavy flow.

Increased production flexibility.

Significant reduction in maintenance and replacement costs.

EXTENDING CHOKE VALVE LIFE