85% of all hydraulically fractured wells use the plug-and-perf method to stimulate multiple zones. Can frac plugs play an important role in improving completion efficiency and well economics? Are frac plugs generally comparable in performance and results?
During horizontal pump-down operations, using the right plug is critical. Made with a proprietary blend of 97 percent premium composite, the TruFrac® plug enables higher run-in speeds and more efficient milling, and it provides superior sealing and anchoring.
Weatherford is the only oilfield services company that manufactures its own composite. We own the entire development process, which gives us complete control of quality. The TruFrac plug is the culmination of more than 10 years of experience and expertise in composite technology. We have researched, designed, and optimized each component to introduce a plug that is unparalleled in its strength, efficiency, and ease of use.
The Weatherford TruFrac composite plug
The Weatherford TruFrac® composite plug provides both single- and multiple-zone isolation during plug-and-perf completions.
The TruFrac composite plug is available in in 4 1/2- and 5 1/2-in. casing sizes and in top-ball and internal-ball configurations. The top-ball design provides a large flow area for communication below the plug while using a ball dropped from the surface to seal off communication during fracturing operations. The internal-ball design eliminates the need to pump a ball down and enables communication from below the plug after fracturing operations.
Benefits
The plug helps to reduce the time required for plug-and-perf completions with faster run-in speeds and quicker mill-out times. This decreases overall rig time and costs.
The predominantly composite material breaks up easily during mill out and produces small, lightweight cuttings that can be easily circulated out of the wellbore without plugging equipment.
The plug is highly durable and can be deployed in diverse environments.
Efficient: Reaches run-in speeds of up to500 ft/min, reduces mill-out time by up to 50%;
Reliable: 10,000 psi 300°F;
Millable: Achieves faster run-in, more efficient milling, and smaller cuttings with a proprietary blend of 97% premium composite material.
The components of TruFrac® composite plug
Molded Element System
The molded element system provides a superior seal and smooth surface that enables run-in speeds of up to 500 ft/min (152 m/min). The seal is proven reliable at pressures up to 10,000 psi (68.9 MPa) and temperatures up to 300°F (148°C). The backup system prevents the element from extruding while it holds pressure.
-Smooth surface;
-Enables run-in speeds of 500 ft/min with reduced risk of flaring, sticking, or presetting;
-Provides a seal that is rated up to 10,000 psi and 300°F;
-Prevents extrusion while holding pressure.
Upper Slip and Cone
Machined from a single piece of proprietary composite, the rigid upper slip and cone, paired with the powdered metal buttons, provide the required anchoring force and easy mill out.
-Combine filament-wound composite structure and powdered-metal buttons;
-Hold setting force in the plug;
-Mills easily.
Lower Slip and Cone
The lower slip uses a combination of high-strength composite and small, hardened inserts to deliver a superior anchoring force with the least amount of metal. This avoids the breakage, spinning, and mill damage that hard and brittle materials such as ceramic can inflict, while enabling effortless milling and reduced cutting size for easy cleaning of wells.
-Combines high-strength composite and small, hardened inserts;
-Provides superior anchoring force with minimal metal;
-Breaks up easily during milling.
The lower cone interfaces with the proprietary slip system and is faceted to eliminate spinning during mill out.
Mule Shoe and Pump-Down Ring
Mule Shoe
The beveled mule shoe acts as a clutch to prevent the composite mandrel from spinning as it is milled. A groove in the mule shoe provides a space for an optional pump-down ring.
-Beveled design;
-Locks onto the plug below it during mill-out;
-Prevents spinning.
Pump-Down Ring
-Optional addition to the mule shoe;
-Decreases the amount of water used to pump each plug to its setting location.
Applications
Single- and multiple-zone plug-and-perf completions;
Vertical, deviated, or horizontal wellbores;
Underbalanced operations.
Case Study
TruFrac® Composite Plug Accelerates Plug-and-Perf Operation with Average Mill-Out Time of 10.5 Minutes
LOCATION: Eagle Ford Shale
WELL TYPE: Onshore, oil
PRODUCTION CASING: 5-1/2 in.,; 23 lb/ft (139.7 mm, 34.2 kg/m)
BOTTOMHOLE TEMPERATURE: 285°F (140.5°C)
TOTAL MEASURED DEPTH: 18,325 ft (5,585 m)
LATERAL LENGTH: 5,667 ft (1,727 m)
CIRCULATING PRESSURE: 6,500 psi (44.8 MPa)
WELLHEAD PRESSURE: 4,000 psi (27.5 MPa)
PRODUCTS/SERVICES: TruFrac 10K top ball frac plug
Objectives
Decrease time on location during the mill-out phase of a plug-and-perf operation.
Our Approach
Weatherford deployed TruFrac composite plugs—made of 97 percent premium composite material— in 26 zones.
The coiled tubing (CT) and rock bit drilled the plugs out in an average time of 10.5 minutes per plug without short trips.
Value to Client
The short length and low metallic content of the TruFrac composite plug helped to reduce mill-out and on-location time, which enabled the operator to begin producing the well faster.
The reduction in on-location time and associated costs improved overall well economics.
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