本文介紹了Forum公司推出的兩種復合橋塞，將進一步推動增產作業優化！
編譯 | 驚蟄 TOM
Forum公司是完井與井下作業的全球供應商，可根據每口井的設計，定制與整合解決方案。近日，Forum能源科技公司推出了ProDril系列復合壓裂橋塞，可在水平井與垂直井的壓裂作業中提供臨時可靠的層位封隔。這些由優質復合材料制成的橋塞是完成多級射孔橋塞聯作作業的關鍵組件。ProDril系列橋塞有助于降低鉆塞作業中的風險，減少非常規完井現場作業時間與費用。
Velocity LSG橋塞
Forum能源科技公司的ProDrill? Velocity LSG復合壓裂橋塞可實現快速磨銑，是完成多級射孔橋塞聯作作業的關鍵組件。該橋塞通過縮短鉆塞時間、減小碎屑尺寸、降低排出碎屑量，提高了完井作業效率。ProDrill Velocity復合橋塞可降低鉆塞作業中的風險，減少非常規井完井的現場作業時間與費用。
該橋塞采用底部坐封與壓縮式坐封的設計，通過電纜接頭組件（WLAK）的張力芯軸減緩受到的沖擊，從而最大限度地降低下入風險，還減小了關鍵元件所受的應力。一旦坐封成功，上述設計可確保壓裂作業期間橋塞起到關鍵作用。
此類橋塞的設計與常規復合橋塞不同，橋塞組件不會在固定芯軸上滑動。優化后的復合橋塞在坐封時長度會縮短，并且在鉆塞作業期間避免組件的旋轉。這款短小的單卡瓦橋塞在鉆塞作業中減少了作業風險與時間。該橋塞采用投球激活方式，可用于5.5in，17至23PPF磅級的套管，額定作業溫度為300℉，額定作業壓力為10000psi。目前正在開發適用于4.5in，9.5至13.5 PPF磅級套管的投球式橋塞。
帶有陶瓷鑲齒的鎂合金卡瓦易于鉆碎，比重可低至1.6，進一步提高了橋塞的使用效率。由于卡瓦材料比復合材料輕，即使井底壓力很低，它也能在鉆塞后保持井筒清潔。
ProDrill? Velocity LSG復合壓裂橋塞的應用優勢包括：1，降低完井作業時間與成本，與傳統復合橋塞設計相比，縮短了65%的鉆塞時間；2，長度縮短50%，因此需要鉆穿并循環出井筒的材料數量降低了50%，使作業風險與鉆塞時間最小化；3，得益于對稱的輕量設計，增加了水平井的泵作業效率，從而減少時間與水資源的消耗；4，采用簡單的單卡瓦、底部坐封、壓縮式坐封設計，可承受碎片沖擊，從而降低風險。
得益于獨特的設計與材質，ProDrill? Velocity LSG復合壓裂橋塞應用特點包括：1，優化后的單卡瓦設計減少了循環出井筒的碎屑數量以及碎屑尺寸；2，壓縮式坐封設計可在坐封過程中避免關鍵組件處于受拉狀態，并可在壓裂過程中與壓裂后，將橋塞保持在坐封位置；3，底部坐封、防提前坐封的結構，可緩解泵送作業期間的沖擊力；4，在鉆塞過程中，凹形球座可避免球旋轉；5，在坐封位置處，獨特的橋塞結構更短，從而減少需要鉆穿以及循環出井筒的材料數量。
ProDrill Express復合橋塞
Forum的ProDril Express復合壓裂橋塞系列可在水平井與直井的水力壓裂作業中，提供可靠、耐用、經濟的方法來臨時封隔層位。該橋塞將復合材料與鑄鐵卡瓦相結合，有助于縮短鉆塞時間（一般為13至20分鐘，甚至更短），同時保持可靠性。
ProDrill Express橋塞采用專利材料制造，多結構接頭能夠穿過芯軸內徑（ID），使其內部完全由復合材料構成。無需黃銅或鋁制轉換配件，從而縮短鉆塞時間并降低作業風險。鑄鐵卡瓦僅硬化至鑲齒深度，可坐封于P110套管。
這種多結構橋塞給予用戶多種選擇，應用更加靈活，僅依靠兩種簡單工具就可改變其應用方式。利用任何電纜坐封工具或管柱送入的水力坐封工具，就可下入該橋塞。目前該系列橋塞可用于以下套管尺寸：3.5in，4.5in，5.5in，7in。
投球式壓裂橋塞
ProDrill Express投球式壓裂橋塞坐封后，內徑保持打開，允許橋塞上方繼續作業。從井口投入密封球，將之泵送到橋塞的球座。一旦球就位，作業者即可對壓裂橋塞施加壓力。若不從井口投入小球，也可將小球置于剪切軸套接頭與芯軸之間，使其成為回流塞。
彈子夾式壓裂橋塞
彈子夾式壓裂橋塞采用簡單的球/籠接頭，在橋塞的上部內徑中裝有3/4in復合球。當橋塞下方區域壓力更大時，這種彈子夾可使下方與上方區域相連通。當上方區域壓力更大時，小球將會進入球座，因此，形成層位封隔。
ProDrill Express投球式壓裂橋塞的應用優勢包括：1、提高作業效率；2、有助于確保壓裂作業中的壓力完整性；3、降低風險；4、降低完井作業成本。應用特點包括：1、可用于多種尺寸規格的套管；2、利用獨特的頂部凸緣設計與底部斜口設計，有助于確保鉆塞時橋塞不會旋轉；3、利用常規油管或連續油管即可鉆塞；4、制造橋塞的材料不會造成環境影響；5、空心卡瓦設計，僅硬化至鑲齒深度，易于鉆出；6、可根據需求泵送刮管器。
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Forum Energy Technologies’ family of ProDrill? composite bridge and frac plugs are designed to reliably provide temporary zonal isolation during stage fracs in horizontal and vertical wells. These plugs, which are a critical component in completing plug-and-perf operations, are constructed with premium composite materials. The plugs help mitigate risk during drillout, while decreasing time on location and costs to complete unconventional wells.
Forum is a global provider of engineered completion and downhole solutions and products that can be tailored and packaged to the technical specifications of each well design.?We’re completely focused on optimizing upstream completion costs for each operator.
ProDrill? Velocity? LSG
The Forum Energy Technologies ProDrill? Velocity? LSG, fast-drillout composite frac plug is a critical component when completing plug-and-perf operations. This solution optimizes well completions efficiency by reducing drillout times, debris size and the amount of material that needs to be circulated out of the hole. The ProDrill Velocity composite plug mitigates risk during drillout, while decreasing time on location and costs to complete unconventional wells.
The set-from-bottom, compression-set plug design minimizes run risk by transmitting impacts through the wireline adapter kit (WLAK) tension mandrel, which also reduces stresses on critical elements of the plug. Once set, this design keeps the plug in the set position during and after fracturing operations.
The design is unique in that the components do not slide on a stationary mandrel like typical composite plugs. This allows the reduced-length, fully optimized composite plug to shorten when set and mitigate spinning components during drillout. The short one-slip plug reduces the amount and size of material that is circulated out of the hole, reducing both risk and time. The plug is available in a top-ball configuration for 5.5. 17-23# casing in 10,000 psi 300F applications. A top ball plug for 4.5-in 9.5-13.5# is currently in development.
With an easily drillable low-specific gravity (LSG) option of 1.6, the magnesium alloy slip, with ceramic buttons, further improves efficiency of the plug. Since the slip’s material is lighter than composite, it provides a clean well post-drillout, even in low bottomhole pressure wellbores.
APPLICATIONS
- Unconventional wells
- Multizone completions
- Plug-and-perf completions
BENEFITS
- Lowers costs and time to complete, up to a 65% reduction in drillout times over traditional composite plug designs
- Minimizes risk and drillout time, with a 50% reduction in length and a 50% reduction in weight of material to be drilled and circulated out of the hole
- Decreases time and water consumption since the symmetrical lightweight design allows more efficient horizontal pumpdown operations
- Mitigates risk with a simple one-slip, set-from-bottom, compression-set design, which withstands debris impacts
FEATURES
- Optimized one-slip design reduces particle size and material to circulate out of hole
- Compression-set design eliminates critical components from being put in tension during the setting sequence and keeps the plug in the locked position during and after fracturing
- Bottom-set, anti-preset configuration mitigates impacts during pumpdown operations
- Recessed ball seat keeps ball from spinning during drillout
- Unique plug configuration that shortens in the set position, reduces amount of material to drill and circulate out of the well
ProDrill? Express Series Composite Plugs?
Forum Energy Technologies’ ProDrill Express Series bridge and frac plugs offer a dependable, durable and cost-effective method to temporarily isolate zones during hydraulic fracturing operations in both vertical and horizontal wells. The plugs uniquely combime composites with cast-iron slips, helping to reduce drillout times (consistent times of 13to20 minutes or less), while remaining reliable
The ProDrill Express plugs are manufactured with proprietary material, which allows the multiconfiguration adapters to be threaded in the inner diameter (ID) mandrel, making it a fully internal composite tool, No brass or aluminum conversion accessories are required, improving drillout times and reducing risks. Cast-iron slips are hardened to wicker depth only, and can be set in up to P110 casing.
The multiconfiguration plug allows the user to easily convert it from a ball-drop solution to a caged-ball flowback or solid bridge plug using two simple kits. The plugs can be run with any wireline-setting tool or tubing-run hydraulic setting tool. Plugs are currently available for the following casing sizes, 3 ”/z, 4’h, 5 1/2, and 7 in.
Ball-Drop Frat Plug Configuration
After the ProDrill Express ball-drop frac plug is set, the ID remains open, allowing work to continue above. A ball is then dropped from the surface and pumped dawn until it seats on the tool. Once the ball is seated, the operator can pressure up against the frac plug, The ball can also be run in place, between the shear sleeve adapter and mandrel allowing it to be used as a flowback plug without having to drop the Gall from surface
Caged-Ball Frac Plug Configuration
The caged-ball frac plug utilizes simple ball/cage adapter that houses a 3/4in composite ball in the upper ID of the plug, When zonal pressure is greater from below the plug, the ball cage allows the lower and upper zones to communicate. When zonal pressure is greater from above, the ball seats; thus, isolating the zones
Bridge Plug Configuration
The Express Series bridge plug is converted using a simple composite bridging pin that is threaded into the mandrel while sealing in the ID. This plugged ID is drilled out before the top slip; thus, allowing the upper and lower zones to equalize during drillout. The operating range listed in the specitication table refers to the difterential pressure rating from above. The differential pressure rating from below is 6000psi.
Benefits
- Increases operational efficiency
- Helps ensure pressure integrity during fracturing operations
- Mitigates risk
- Decreases amount of inventory needed on hand
- Reduces cost of completions
Features
- Available in 3 ?, 4 ?, 5, 5 ? and 7 in. casing sizes
- Utilizes unique lug design on the top and muleshoe bottom, helping ensure that the plugs do not spin during drillout
- Can be drilled using conventional tubing or coiled tubing
- Materials used in construction are conducive to a wide range of environments
- Hollowed slip design only hardened to wicker depth for ease of drillout
- Pump-down wiper available upon request
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