Increasing Efficiencies During Cased Hole Fracturing Operations Through Frac Plug Material Selection

Abstract

Plug and Perf (P&P) still remains one of the most prolific methods used in multi-stage hydraulic fracturing operations. Recent changes in the materials chosen to manufacture frac plugs is leading to increased efficiencies during installation as well as the plug milling phase of P&P operations. Historically, the fluid diversion devises used in multi-stage hydraulic fracturing operations have been manufactured using mainly glass/epoxy based composite materials and in recent years, in an effort to increase efficiencies, disintegrating materials. Most efforts have been focused on reducing the amount of metallic parts as well as reducing the overall amount of material used to manufacture these plugs in an effort maintain plug performance during fracturing operations while reducing time/costs during post-frac milling operations by making plug removal more efficient. Recent advances in metallic based composite materials are allowing for plugs to be manufactured out of light weight alloys that are higher strength than traditional composite plug materials while also being easier to remove and circulate out during plug milling operations. Also, because the materials are not designed to disintegrate, there is no need to consider fluids that the plugs will be exposed to thus ensuring a high performance plug without the careful balancing act between an environment that causes the plug to disintegrate too fast or not at all. In addition to this, changes in how slips and packing elements are being designed is allowing for additional gains in efficiencies during plug deployment and removal. Using real-world results, we can now demonstrate how these design changes can allow for a new level of operational efficiencies not previously available in P&P operations.