When it comes to unconventional wells, plug-and-perf is a popular completion option because of the extended stage potential and larger inside diameter (ID) production flow area versus ball and sleeve systems. But, when composite plugs are used to isolate zones the startup of production can be delayed as long as three or more days while the plugs and drop balls are drilled out using coiled-tubing (CT)-conveyed milling tools and debris is circulated to the surface. This not only prolongs completion times, it results in
Additional planning
More days on location
Increased HSE risk
Potential stuck incidents
Limited plug setting depths
Location restrictions
Historically, intervention has been unavoidable in plug-and-perf completions. Last year alone, operators set over 250,000 frac plugs in North American wells and spent more than 30,000 days milling them out before production could begin. But it doesn’t have to be that way. The Baker Hughes SHADOW series frac plug allows you to bypass CT intervention and start producing as soon as fracturing operations are complete. The plug is designed to stay downhole and completely eliminates the millout phase of plug-and-perf operations, increasing operational efficiency and maximizing pay zone access.
The SHADOW series frac plug is a permanent millable plug designed to be left downhole during production, completely eliminating the plug drillout phase of plug-and-perf completions. The plug features a large flow-through inside diameter (ID) and uses Baker Hughes IN-Tallic disintegrating frac balls so production can flow with the plugs in place, shaving days off of completion times, and eliminating the cost and risk associated with coiled tubing (CT) intervention.
IN-Tallic disintegrating frac balls are made of controlled electrolytic metallic (CEM) nanoconstructed material—a technology pioneered by Baker Hughes. IN-Tallic balls hold pressure during fracturing operations, then completely disintegrate in the well when exposed to produced fluids to prevent production blockages and eliminate debris. IN-Tallic balls are stronger than composite frac balls and can withstand higher pressures without deformation, enabling a larger ID through the plug.
SHADOW frac plugs are run in hole on wireline and are set in sequence along the lateral section of the wellbore to isolate zones for treatment, just like composite plugs. The plugs can be set with our field-proven E-4 setting tool, which has been deployed in thousands of wells. Initial access to the reservoir is created using our Alpha sleeve pressure-actuated valve, rather than a perforating gun run in on coiled tubing.
Zones can be independently treated after dropping an IN-Tallic frac ball to seal off the plug. Multiple plugs can be run to isolate multiple zones, and commingled testing and production of zones both above and below the plug can occur once a higher pressure differential from below is established. Flowing back after treatment is not hindered due to the SHADOW plug’s enlarged ID.
Because the plugs stay in the well, they are ideal for extended wellbores and for developments in remote locations where it may be difficult to procure a CT unit. And SHADOW plugs can be set in horizontal sections deeper than the reach of CT, allowing operators to expose more of the reservoir to the wellbore and maximize access to their pay zones.
Applications
Unconventional oil and gas wells
Staged plug-and-perf completions
Horizontal wellbores
Extended-reach wellbores
Features and Benefits
Large flow-through ID
– Allows production without post-frac intervention
– Permits flowback after zone treatment
No coiled tubing intervention
– Lessens the amount of time spent on location
– Reduces completion costs
– Allows plugs to be set deeper in horizontal sections
– Lets operators develop remote reservoirs where it may be difficult to procure a CT unit
IN-Tallic disintegrating frac balls
– Assure flow before or shortly after the well is put on production
– Enable fracturing of more stages at higher pressures
– Allow a larger ID through the plug
Antirotation clutching feature
– Maximizes removal efficiency if milling is required
Case study
Case one: SHADOW Frac Plugs Eliminated Post-Frac Intervention and Saved USD 300,000
Location: Horn River Basin, British Columbia
Results
Provided an interventionless solution that matched the production performance of composite plugs
Saved operator USD 300,000
Eliminated costs and risks associated with post-frac intervention
Allowed production to begin immediately after fracturing operations
Reduced time on location
Background and challenges
Seven-well pad
5.5-in. 20lb/ft casing
Operator needed a solution to increase efficiency and reduce cost
Operator agreed to complete two entire wells with SHADOW plugs
Ran composite plugs in other five wells
Baker Hughes solution
Deployed a total of 52 SHADOW frac plugs with IN-Tallic disintegrating frac balls across two wells
Eliminated coiled-tubing drillout on two wells of seven-well pad
Ball seat signatures were clearly visible on pump charts
Wells with SHADOW produced at the same volume as the five wells completed with composite plugs
Case two: SHADOW plugs enabled interventionless plug-and-perf completion at record depth, saved USD 50,000
Location: Williston Basin
Results
Eliminated milling, saving two days of drillout time and an estimated USD 50,000
Enabled plug-and-perf completion in lateral depths unreachable by coiled tubing
Reduced risk of pre-setting with impact-resistant SHADOW plug design
Challenges
25,400-ft measured depth well
15,000-ft lateral section
Needed interventionless equipment for deepest treatment stages Baker Hughes solution
Deployed 30 size 368 SHADOW plugs to isolate 31 production stages in the deepest part of the well lateral, where coiled tubing is not an option
Used IN-Tallic frac balls to seal the plugs during treatment delivering an interventionless plug-and-perf completion solution
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