The trial aimed to compare the performance of ClareTech HFL with the Service Contractor’s existing valve lubricant (termed ‘EVL’ for this report).
Full Field Trial with ClareTech HFL For OEM Frac Service Contractor and Operator
The Problem
Two frac tree and manifold valve ‘pairs’ were prefilled with ClareTech HFL, and another two frac tree/manifold valves were filled with the existing grease. The frac job was with Slickwater over 49 stages. The valves with ClareTech HFL were re-greased every eight stages, the existing grease was injected every four stages, as was standard. Valve function and sealing integrity would be monitored over the job, and also how much grease is injected into the valves each time. The frac tree/manifolds remained on the wells for all the flowback and testing operations which ran for several weeks. During this phase, no valves were re-greased. After rig down, all valves were taken back to the workshop for 15,000 psi pressure testing, to test valve seal integrity with no grease injection, valve cycling or maintenance. If the valves leak, they would be cycled twice, injected with grease, and tested again. After this initial post-job pressure testing, the valves were then stripped down to inspect the condition of the internal components and how much grease and/or sand was in the valve cavities.
The Solution
- No valve problems observed during the job.
- During field re-greasing, it was noted that valves with ClareTech HFL required approx. 50% less grease to be injected each time compared
with the EVL. - Post job workshop pressure testing. All valves filled with ClareTech HFL successfully tested first time. Several valves with EVL failed the first test, and some failed the second test.
- Valve inspections: Valves with ClareTech HFL had minimal sand in the cavities, some valves had zero sand and the grease was in good condition. Valve gates/seats in good condition overall. Some with slight damage still passed pressure test due to ClareTech HFL’s sealing assistance.
- Valves with EVL had less grease and more sand in the cavities, the grease was a lot drier than Claretech HFL. More damage on gates/seats.
- Overall, with extended stage re-greasing and less grease injected each time, there was four times less ClareTech HFL grease consumed compared to the amount of EVL used.
The results of this field trial saw ClareTech HFL be fully approved with this OEM and used in multiple operations across the US.
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