Completion Products 2014 Catalog
Transcription
Completion Products 2014 Catalog
Smart Solutions. Powerful Products. Completion Products 2014 Catalog 1 Smart Solutions. Powerful Products. At Forum, we are here for one reason: to serve as your trusted ally in the oilfield. With our comprehensive range of mission-critical expertise, we deliver precisely what you need when you need it — from drilling equipment to custom solutions, subsea technology to production equipment, engineering support to repair services. Forum Energy Technologies brings together some of the most well-known brands in our industry with an extensive range of mission critical products and services. We are building a world class company to bring innovative solutions to our worldwide customers. With offices in the key oilfield distribution centers of the globe, Forum is well-positioned to supply our clients with the equipment and related services that improve safety and performance and lower operating costs. Forum’s products and services range from the underwater reservoir to the refinery, from the sea floor to the above ground transportation line. We pride ourselves on giving you a comprehensive offering of solutions to maximize your operations and improve your bottom line. Our customers are our partners and we work with them to solve their ever-changing challenges. Completion Products 2014 Catalog For over 30 years, the makers of ProDrill products have been involved in the manufacturing and distribution of high quality, high value completion tools for the oil and gas industry. Now a part of the Forum brand portfolio, Completion Products will continue to provide tools and equipment that exceed required applications and provide real value to customers. Our extensive experience domestically and internationally enables us to provide solutions for today’s more technically difficult environment. All the tools in our catalog are field proven. Specialized tools for unique problems can be engineered and built to customer’s specifications. The Express Series composite multi-configuration plugs were developed in 2011. Since then, over 30,000 units have been run in both horizontal and vertical applications in every major U.S shale play as well as in international markets. The Express Series is the first plug to offer the ability to change from a Ball Drop to a Bridge or Caged Ball Flowback Plug without adding any significant metal components to the tool while maintaining a fully composite mandrel. Express Series Composite Plugs..............................2 Plug Millout Case History 2...................................14 Ball Drop Frac Plug...............................................................3 Plug Millout Case History 3...................................15 Caged Ball Flowback Plug....................................................3 Composite Material................................................16 Bridge Plug...........................................................................3 Slips..........................................................................16 Plug Specifications...............................................................4 Express Series Setting Equipment........................17 Quality Assurance....................................................5 Performance Verification Data 5 ½" 10K 300 Degrees.....6-7 Baker No. 10 Setting Adapter Kit.......................................19 Performance Verification Data 7" 10K 300 Degrees.......8-10 Baker No. 20 Setting Adapter Kit.......................................20 Benefits...................................................................11 “GO” 3625 Setting Adapter Kit.........................................21 Baker No. 05 Setting Adapter Kit.......................................18 Multi-Configuration...........................................................11 Plug / Setting Tool Assembly.................................22 Plug Removal.....................................................................11 Running in Hole......................................................23 Plug Millout Returns..........................................................12 Plug Removal.....................................................24-25 Plug Millout Case History 1...................................13 Flow Control Completion Products.......................26 1 Express Series Composite Plugs The Patent Pending Forum ProDrill Express Series Bridge and Frac Plugs utilize a unique combination of proprietary composites to provide a dependable, durable, and cost-efficient method for temporary zone isolation during stage fracs in both vertical and horizontal applications. Forum ProDrill Plugs are manufactured with proprietary material that allows threading of multi-configuration adapters in the inner mandrel (ID) making it a true fully internal composite tool. No brass or aluminum conversion accessories are required. Plugs are currently available for the following casing with other sizes under development: 3 ½", 4 ½", 5", 5 ½", 7". Multi-Configuration • By utilizing simple accessories, a single composite plug can be easily converted in the field from a Ball Drop Frac Plug to either a Solid Bridge Plug or a Caged Ball Flowback Plug. • Conversion is easily accomplished using a flathead screwdriver for the Bridging Pin or wrench for the Caged Ball Adapter. • With the exception of the spring and aluminum spring seat, there is no other addition of metallic components needed to convert the plugs. • The Bridging Pin and Caged Ball Adapter housing are constructed entirely from composite. Material • Materials used in construction are conducive to a wide range of environments. • No need for metallic material to be used in mandrel for burst/ collapse reinforcement. • Ability to thread Bridging Pin / Caged Ball Adapter directly into mandrel ID w/o utilizing brass/aluminum. • No need for pins/bond to strengthen the bottom mandrel / shoe connection. Slips • Traditional Gray Cast iron slips. • Heat treated to wicker depth only. • 50-60 HRC with a case depth of .040-.050". • Holes drilled entirely through slip segments, which allows segment to break into smaller pieces during millout. • 3 ½" Plugs are set using Baker #5, 1 11/16" GO, and 2 1/8" GO setting tools. • 4 ½" Plugs are set using Baker #10, 3 5/8" GO Compact and 3 ½" GO Shorty setting tools. • 5" Plugs are set using Baker #10, 3 5/8" GO Compact and 3 ½" Go shorty setting tools. • 5 ½" Plugs are set using Baker #10, Baker #20, 3 5/8" GO Compact and 3 ½" GO Shorty setting tools. • 7" Plugs are set using Baker #20, 3 5/8" GO Compact and 3 ½" GO Shorty setting tools. Plug Removal • Can be drilled using conventional or coiled tubing. • Field proven typical drill times of 10-20 minutes or less. • Sets securely in up to P110 casing. • Cuttings easily circulate back to the surface. • Cast Segmented Slips also available. Plug Ratings Running / Setting • Compact and easy running. • Running speeds of up to 300 feet per minute depending on well conditions. • Plugs are set using a universal setting sleeve and shear sleeve adapter. 2 • Simple, efficient method of attaching plug to setting tools. • 3 ½" – Up to 10,000 PSI and 300 Degrees F. • 4 ½" – Up to 10,000 PSI and 350 Degrees F. • 5" – Up to 10,000 PSI and 300 Degrees F. • 5 ½" – Up to 10,000 PSI and 350 Degrees F. • 7" – Up to 10,000 PSI and 300 Degrees F. Ball Drop Frac Plug After the Ball Drop Frac Plug is set, the inner diameter remains open • The Caged Ball Adapter provides a double O-Ring seal in the ID of the mandrel. thus allowing wireline operators to continue work above. A ball is • ¾" Composite Ball is spring held on seat so while being RIH, fluid then dropped from the surface and pumped down until it seats on is bypassed around the plug and not through the ball seat. This the tool. Once the ball is seated, the operator can pressure up against helps maintain the credibility of the ball seat while being RIH. the Frac Plug. The Shear Sleeve Adapter used to set the plugs is designed so that the user can, if needed, run the Drop Ball “in place” inside the Adapter. This gives the user the choice to utilize the plug as • Once plug is set, ball prohibits pressure/fluid from above while allowing pressure/fluid from below. a Flow Back Plug without having to drop the ball from the surface. • Caged Ball Adapter is easily installed/removed using a wrench. • Utilizes a machined Composite Frac Ball with a Specific Gravity Bridge Plug of 1.9. • While on seat, the ball is below the top of the plug in order to reduce ball bearing effect during mill out. The Express Series Bridge Plug is converted using a simple composite “Bridging Pin” that is threaded into the mandrel while sealing in the Inner Diameter. This plugged ID is drilled out before the top slip, allowing the upper and lower zones to equalize during drill Caged Ball Flowback Plug out. Operating range listed in the specification table refers to the The Express Series Caged Ball Frac utilizes a simple Ball / Cage Adapter differential pressure rating from above. The differential pressure rating that houses a ¾" composite ball in the upper ID of the plug. When from below is 6,000 psi. zonal pressure is greater from below the plug, the ball cage allows the lower and upper zones to comingle. When zonal pressure is greater from above, the ball seats thus isolating the zones. • To convert a Ball Drop Frac plug for Flowback applications, a composite Caged Ball Adapter is threaded into the ID of the top of the mandrel. • The Bridging Pin provides a double O-Ring seal in the ID of the mandrel, thus blocking the flow from both above and below. • Pin is drilled out before the top slip so that the zones equalize before the slip is removed and released from the casing. • Pin is easily installed/removed using a screwdriver. 3 Express Series Plug Specifications CASING CASING WT. Min ID Max ID Tool O.D. Tool ID Drop Ball Size Caged Ball ID Caged Ball Size Operating Range 3 ½" 9.3-10.2# 2.827" 2.992" 2.725" .625" 1.250" .375" .625" 10K, 300°F 4 ½" 15.1-17.1# 3.650" 3.826" 3.440" .750" 1.688" .500" .750" 8K 275°F 10K 300°F 4 ½" 9.5-13.5# 3.826" 4.090" 3.609" .750" 1.688" .500" .750" 6K 250°F 8K 275°F 10K 300°F 10K 350°F 5" 18-23.2# 3.919" 4.276" 3.688" .750" 1.688" .500" .750" 10K 300°F 5 ½" 13-20# 4.580" 5.044" 4.425" 1.000" 2.000" .500" .750" 6K 250°F 8K 275°F 10K 300°F 10K 350°F 5 ½" 23-26# 4.423" 4.670" 4.188" 1.000" 2.000" .500" .750" 10K 300°F 7" 23-32# 5.830" 6.366" 5.635" 1.500" 2.250" 1.000" 1.250" 7" 17-23# 6.276" 6.538" 6.005" 1.500" 2.250" 1.000" 1.250" Custom O.D.s available Other sizes under development 4 8K 275°F 10K 300°F 8K 275°F 10K 300°F Quality Assurance At Forum Completion Products we understand that our plug design, composite technology and quality directly correlate to the optimal well completion. To ensure consistent reliability of our plugs we have stringent quality assurance and testing procedures for all threaded components on our plugs. 1% of all Critical Component Raw Material Shear Tested to Destruction Critical female threaded components sectioned for visual inspection 100% Traceability of every critical component of our plugs 100% Thread Gauging of every male and female thread Destructive Thread Testing of 1% of Critical Components 5 Performance Verification Data 5 ½" 10K 300 Degrees The setting force required to set the plug was approximately 29,385 lbs. The plug was witnessed shearing in the test fixture inside the well at 3,000 PSI on the calibrated gauges on pressure control manifold. The curve in Figure 5b shows the setting action of the plug in approximately 1 minute and 30 seconds. 0:10:51 0:10:21 0:09:52 0:09:22 0:08:52 0:08:23 0:07:53 0:07:24 0:06:54 0:06:24 0:05:55 0:05:25 0:04:56 0:04:26 0:03:56 0:03:27 0:02:57 0:02:28 0:01:58 0:01:28 0:00:59 Time 300 290 280 270 260 250 0:00:29 Temp in Deg °F Temperature on Plug Sample A During Set 7-29-13 Figure 5a Setting Plug Sample A 7-29-13 Pressure (PSI) 3500 3000 2500 2000 1500 1000 500 Time Figure 5b 6 0:00:08 0:00:16 0:00:25 0:00:33 0:00:42 0:00:50 0:00:58 0:01:07 0:01:15 0:01:24 0:01:32 0:01:40 0:01:49 0:01:57 0:02:06 0:02:14 0:02:22 0:02:31 0:02:39 0:02:46 0:02:56 0:03:04 0:03:13 0:03:21 0:03:30 0:03:38 0:03:46 0:03:55 0:04:03 0:04:12 0 2:07:35 2:01:47 1:55:59 1:50:11 1:44:23 1:38:35 1:32:47 1:26:59 1:21:11 1:15:23 1:09:35 1:03:47 0:57:59 0:52:11 0:46:23 0:40:35 0:34:47 0:28:59 0:23:11 0:17:23 0:11:35 0:05:47 310 305 300 295 290 285 280 275 Time Temperature in Deg°F Heat Up After Set on Plug Sample A During Cycles 7-29-13 Figure 6a 2:08:41 2:03:55 1:59:09 1:54:23 1:49:37 1:44:51 1:40:05 1:35:19 1:30:33 1:25:47 1:21:01 1:16:15 1:11:29 1:06:43 1:01:57 0:57:11 0:52:25 0:47:39 0:42:53 0:38:07 0:33:21 0:28:35 0:23:49 0:19:03 0:14:17 0:09:31 0:04:45 14000 12000 10000 8000 6000 4000 2000 0 Time Pressure (PSI) Cycle at Temperature Above Plug Sample A 7-29-13 Figure 6b Performance Verification Data 5 ½" 10K 300 Degrees The 5 ½" - 20# - 10,000K composite plug successfully tested to 10,000 PSI and 300°F from annulus above. The plug was successfully set with approximately 29,385 lbs. of force at 275°F and held 8,000 PSI from above for 5 minutes at 275°F. Once the plug successfully completed the 8,000 PSI hold, temperature was increased while maintaining 8,000 PSI above the plug. Once 300°F was reached, pressure was increased to 10,000 PSI. Once this hold was completed, pressure was increased to 11,000 PSI, and was held for 5 minutes. Finally, continuous pressure was applied to the plug in attempt to achieve a safety factor failure. This failure did occur at a pressure of 12,500 PSI from annulus above. 7 Temperature In Deg °F Temperature On Plug During Set Test 2 5-29-12 270 260 250 240 230 220 1 35 69 103 137 171 205 239 273 307 341 375 409 443 477 511 545 579 Time in Minutes - 3.8 mins Figure 7a Setting Plug Test 2 5-29-12 Pressure (PSI) 5000 4000 3000 2000 1000 0 -1000 1 9 17 25 33 41 49 57 65 73 81 89 Time in Seconds - 48 secs Figure 7b Performance Verification Data 7" 10K 300 Degrees The composite plug was lowered into the hot oil bath. The oil bath had stabilized at 250°F (+/-10°). The plug was allowed to soak at temperature for approximately 30 minutes. The temperature is shown to be 250°F the last 1/3 of the curve, and that is when the plug was set. (See Figure 7a) The setting force in the plug was approximately 41,118 lbs. The plug was witnessed shearing in the test fixture inside the well at 4,200 PSI on the calibrated gauges on the pressure control manifold. The curve on Fugure 7b shows the setting action of the plug. In the curve the first two peaks indicate slips breaking between 1,000 and 2,000 PSI. 8 97 105 113 121 Temperature In Deg °F Temperature On Plug During Cycles Test 2 5-29-12 350 300 250 200 1 166 331 496 661 826 991 1156 1321 1486 1651 1816 1981 2146 Time in Hours - 2.12 hrs Figure 8a 1st Pressure Cycles Above Plug Test 2 5-29-12 Pressure (PSI) 12000 10000 8000 6000 4000 2000 0 -2000 1 136 271 406 541 676 811 946 1081 1216 1351 1486 1621 1756 Figure 8b Performance Verification Data 7" 10K 300 Degrees The curve in Figure 8a shows the temperatures being 245°F up to 307°F during the 1st pressure cycle above the bridge plug. The curve in Figure 8b shows the observed results of the test with applied pressure from above during the 1st pressure cycle @ 245°F up to 307°F. 9 +10K - +300F Pressure Dwell 5-29-12 12000 !! !! !! 8000 6000 4000 2000 0 -2000 !! !! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! Pressure (PSI) 10000 1 ! !! 98 195 292 389 486 583 680 777 874 971 1068 1165 Figure 9a Performance Verification Data 7" 10K 300 Degrees 10 The plug was taken to the target testing pressure of 10K PSI, and maintained a 3 minute pressure dwell at 244°F. Once the pressure The plug was taken to 10,000 PSI and 250°F, as shown in the dwell was completed the heating system was fired to increase curve in Figure 8b. The plug maintained each pressure dwell of 3 temperature up to +300°F, while maintaining the 10K above minutes up to the target testing pressure of 10K. After successfully the plug during the heat up. In the curve above you can see as completing the last 3 minute pressure hold at 10k and 250°F, temperature rises the pressure was increasing, resulting in the need pressure would be held at 10K and temperature was increased up to bleed off pressure in increments of -500 PSI five times, in order to 300°F. Pressure kept increasing during the heat up period, as it to keep the testing pressure within the tolerance of the testing did, pressure was bled off in increments of -500 PSI, to stay within procedure requirements. Wireline Solutions decided to stop bleeding the tolerances of the test procedure requirements during the 10K pressure until pressure reached 11,000 PSI. At 11K the plug saw pressure dwell. The curve on Figure 9a shows the observed results temperatures up to 307°F, where after a hold time of 1.37 hours of the test with applied pressure from above during the 10K – 11K was reached, a failure occurred and pressure equalized between pressure dwell @ 244°F up to 307°F. annulus above and annulus below. Multi-Configuration • By utilizing simple accessories, a single composite plug can be easily converted in the field from a Ball Drop Frac Plug to either a Solid Bridge Plug or a Caged Ball Flowback Plug. • This can be easily accomplished in the field using a flathead screwdriver for the Bridging Pin or wrench for the Caged Ball Adapter. • With the exception of the spring and aluminum spring seat, there is no other addition of metallic components needed to convert the plugs. • The Bridging Pin and Caged Ball Adapter housing are constructed entirely from composite. • No metal in mandrel ID whatsoever. Plug Removal • Plugs can be drilled using conventional or coiled tubing. • Slips are hardened to wicker depth only for ease of drill out. • Utilizes unique “Lug” design on the top and muleshoe bottom ensuring that the plugs do not spin during drill out. Lug shoe bottom also available on 4 ½" and 5 ½" Sizes. • Field proven mill times of 10-20 minutes or less. 11 Plug Millout Returns 12 Plug Millout Case History 1 DATE: May 5, 2012 PLUG TYPE: 5 1/2" 10K Ball Drop Frac (ECFP-5500-002) QUANTITY: 24 WELL DETAILS: 5 1/2" 17# Casing, Approximately 14,000’ ft with 7300’ lateral B.H.T: 170 Degrees Fahrenheit FRAC DETAILS: 100 bbls/minute at approximately 8,500 psi MILL DETAILS: JZ Rock Bit w/ CT Agitator on 2" Coiled Tubing Klbs AVERAGE PLUG MILL TIME: 22 minutes 6 60 5 50 4 40 3 30 2 20 1 10 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 WOB (lbs) 2.5 2.5 1.5 2 Pump Rate (bpm) 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 3 2 2.5 2.5 2.5 2.5 2.5 0.5 1 1.5 1 3 3 3 1 1 1 1 2 2 5 5 3 2 3 3 3 2.8 2.8 3 3 3 3 3 0 Mill out time (mins) 13 16 21 53 13 32 15 13 15 37 12 8 10 14 13 14 10 35 47 25 13 21 43 44 Plugs - 5.5 10K Ball Drop Frac (ECFP-5500-002) 13 Plug Millout Case History 2 PLUG TYPE: 5 1/2" 6K Bridge (ECBP-5500-000) LOCATION: Permian Basin WELL DETAILS: Vertical wells Milled w/ Coiled Tubing 14 # Date Casing Grade BHT Fluid Plug Depth Fluid Level Surface PSI Max Frac Pressure Mill Date Mill Type Coil WOB RPM Rotary/ Motor Mill Time Fluid Type Fluid Weight Flow Rate Fwd/ Rev 1 03/08/12 5 1/2 N80 160 Slick 10,567 full 3100 4800 3-Apr butterfly 2" CT 2500 383 Motor 7 min fresh 8.33 2.5 bbls fwd 2 03/08/12 5 1/2 N80 160 Slick 10,307 full 2700 4800 3-Apr butterfly 2" CT 2500 383 Motor 12 min fresh 8.33 2.5 bbls fwd 3 03/08/12 5 1/2 N80 160 Slick 10162 full 2900 4800 3-Apr butterfly 2" CT 2500 383 Motor 15 min fresh 8.33 2.5 bbls fwd 4 03/08/12 5 1/2 N80 160 Slick 9962 full 3000 4800 3-Apr butterfly 2" CT 2500 383 Motor 7 min fresh 8.33 2.5 bbls fwd 5 03/09/12 5 1/2 N80 160 Slick 9587 full 2600 4500 3-Apr butterfly 2" CT 2500 383 Motor 17 min fresh 8.33 2.5 bbls fwd 6 03/09/12 5 1/2 N80 160 Slick 9,372 full 2400 4200 3-Apr butterfly 2" CT 2500 383 Motor 14 min fresh 8.33 2.5 bbls fwd 7 03/09/12 5 1/2 N80 160 Slick 9177 full 2100 4200 3-Apr butterfly 2" CT 2500 383 Motor 8 min fresh 8.33 2.5 bbls fwd 1 04/18/12 5 1/2 N80 160 Slick 9540 full 4300 4800 26-Apr butterfly 2" CT 2500 425 Motor 3 min fresh 8.33 3 bbls fwd 2 04/18/12 5 1/2 N80 160 Slick 9270 full 4000 4800 26-Apr butterfly 2" CT 2500 425 Motor 3 min fresh 8.33 3 bbls fwd 3 04/18/12 5 1/2 N80 160 Slick 9080 full 3780 4800 26-Apr butterfly 2" CT 2500 425 Motor 2 min fresh 8.33 3 bbls fwd 4 04/19/12 5 1/2 N80 160 Slick 8690 full 3500 4500 26-Apr butterfly 2" CT 2500 425 Motor 3 min fresh 8.33 3 bbls fwd 5 04/19/12 5 1/2 N80 160 Slick 8502 full 3200 4500 26-Apr butterfly 2" CT 2500 425 Motor 3 min fresh 8.33 3 bbls fwd 6 04/19/12 5 1/2 N80 160 Slick 8175 full 2700 4100 26-Apr butterfly 2" CT 2500 425 Motor 4 min fresh 8.33 3 bbls fwd 7 04/19/12 5 1/2 N80 160 Slick 7900 full 2400 4200 26-Apr butterfly 2" CT 2500 425 Motor 3 min fresh 8.33 3 bbls fwd 8 04/19/12 5 1/2 N80 160 Slick 7,670 full 2100 3500 26-Apr butterfly 2" CT 2500 425 Motor 3 min fresh 8.33 3 bbls fwd 9 04/20/12 5 1/2 N80 160 Slick 7,422 full 1800 3500 26-Apr butterfly 2" CT 2500 425 Motor 2 min fresh 8.33 3 bbls fwd 10 04/20/12 5 1/2 N80 160 Slick 7190 full 1700 3500 26-Apr butterfly 2" CT 2500 425 Motor 4 min fresh 8.33 3 bbls fwd 11 04/20/12 5 1/2 N80 160 Slick 6700 full 1200 3500 26-Apr butterfly 2" CT 2500 425 Motor 2 min fresh 8.33 3 bbls fwd 1 04/30/12 5 1/2 N80 160 Slick 10322 full 4000 4800 7-May roller cone 2" CT 2500 425 Motor 10 min fresh 8.33 3 bbls fwd 2 04/30/12 5 1/2 N80 160 Slick 10117 full 3400 4800 7-May roller cone 2" CT 2500 425 Motor 8 min fresh 8.33 3 bbls fwd 3 04/30/12 5 1/2 N80 160 Slick 9927 full 3500 4500 7-May roller cone 2" CT 2500 425 Motor 21 min fresh 8.33 3 bbls fwd 4 04/30/12 5 1/2 N80 160 Slick 9467 full 3400 4500 7-May roller cone 2" CT 2500 425 Motor 7 min fresh 8.33 3 bbls fwd 5 04/30/12 5 1/2 N80 160 Slick 9307 full 3300 4500 7-May roller cone 2" CT 2500 425 Motor 10 min fresh 8.33 3 bbls fwd 6 04/30/12 5 1/2 N80 160 Slick 9127 full 3600 4500 7-May roller cone 2" CT 2500 425 Motor 11 min fresh 8.33 3 bbls fwd 7 04/30/12 5 1/2 N80 160 Slick 8937 full 3200 4500 7-May roller cone 2" CT 2500 425 Motor 7 min fresh 8.33 3 bbls fwd 8 05/01/12 5 1/2 N80 160 Slick 8717 full 2500 3500 7-May roller cone 2" CT 2500 425 Motor 8 min fresh 8.33 3 bbls fwd 9 05/01/12 5 1/2 N80 160 Slick 8462 full 2000 3500 7-May roller cone 2" CT 2500 425 Motor 17 min fresh 8.33 3 bbls fwd 10 05/01/12 5 1/2 N80 160 Slick 8091 full 1050 3200 7-May roller cone 2" CT 2500 425 Motor 10 min fresh 8.33 3 bbls fwd 1 04/17/12 5 1/2 N80 160 Slick 10177 full 3900 4800 8-May roller cone 2" CT 2500 425 Motor 5 min fresh 8.33 3 bbls fwd 2 04/17/12 5 1/2 N80 160 Slick 9977 full 3700 4800 8-May roller cone 2" CT 2500 425 Motor 3 min fresh 8.33 3 bbls fwd 3 04/18/12 5 1/2 N80 160 Slick 9817 full 2600 4500 8-May roller cone 2" CT 2500 425 Motor 4 min fresh 8.33 3 bbls fwd 4 04/18/12 5 1/2 N80 160 Slick 9657 full 2600 4500 8-May roller cone 2" CT 2500 425 Motor 3 min fresh 8.33 3 bbls fwd 5 04/18/12 5 1/2 N80 160 Slick 9477 full 2800 4500 8-May roller cone 2" CT 2500 425 Motor 5 min fresh 8.33 3 bbls fwd 6 04/18/12 5 1/2 N80 160 Slick 9047 full 2500 4500 8-May roller cone 2" CT 2500 425 Motor 3 min fresh 8.33 3 bbls fwd 7 04/18/12 5 1/2 N80 160 Slick 8877 full 1900 4200 8-May roller cone 2" CT 2500 425 Motor 3 min fresh 8.33 3 bbls fwd 8 04/18/12 5 1/2 N80 160 Slick 8727 full 2200 3500 8-May roller cone 2" CT 2500 425 Motor 2 min fresh 8.33 3 bbls fwd 9 04/19/12 5 1/2 N80 160 Slick 8562 full 1900 3500 8-May roller cone 2" CT 2500 425 Motor 3 min fresh 8.33 3 bbls fwd 1 04/10/12 5 1/2 N80 160 Slick 8410 full 3100 4500 3-May roller cone 2" CT 2500 425 Motor 3 min fresh 8.33 3 bbls fwd 2 04/10/12 5 1/2 N80 160 Slick 8200 full 2800 4500 3-May roller cone 2" CT 2500 425 Motor 4 min fresh 8.33 3 bbls fwd 3 04/10/12 5 1/2 N80 160 Slick 8035 full 2500 4200 3-May roller cone 2" CT 2500 425 Motor 3 min fresh 8.33 3 bbls fwd Plug Millout Case History 3 Well Name: Blackstone McMahon B28 #1H County: San Augustine Work String: 2" CT Motor Type: NOV Motor Size: 2.875" Fluid Type: Fresh BHT: 225 Degrees °F DATE TIME 01/31/14 0600 1700 1720 1730 1745 1800 2200 0035 0048 0107 0122 0202 0212 0242 0300 0335 0420 0517 0541 0120 0631 0657 0710 0752 0835 0847 0920 1110 1150 1301 1307 1319 1334 1353 1408 1422 1730 1735 1743 1757 1857 1903 1931 1 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5 1800 1800 1800 1800 1900 1850 1900 1850 1850 1850 1850 1800 1800 1600 1600 1800 1800 1700 1800 1800 1800 1800 1500 1600 1600 1600 1500 1600 1600 1600 4100 4100 4100 4100 4200 4200 4400 4400 4400 4000 4250 4250 4400 4400 4130 4150 3900 4200 4100 4100 4000 3900 4000 3900 4000 3800 3900 3900 4200 2.5 2.5 2.5 2.5 2.5 2.5 3.5 3.5 3.5 3.5 3.5 3.5 1500 1500 1500 1500 1550 1500 3700 3700 3900 4200 4200 4200 0015 1.75 1.75 1500 3200 0021 0330 0500 0510 2.5 02/01/14 02/01/14 02/02/14 0520 0900 1735 1900 PUMP RATE RETURN RATE WELL PSI 2 PUMP PSI 2700 2600 COMMENTS Standby, waiting for frac to move out & ctu move in rig up put on etc and pull test to 20 & 25k , load coil, drf ted ctc, dual flapper & jars with 15/16" ball, drifted disconnect with ¾" ball AOL relieve Heath MU BHA, test BHA to 2bpm CP 2700psi Rigging up riser to BOP. remove BOP mill will not pass. (pressure lock) during BOP tes Open well, RJH Tag plug #1 @ 9572ft. Plug #1 gone 13min. Plug 5bbl gel sweep Tag plug #2 @ 10054ft. Plug #2 gone 15min. Plug 5bbl gel sweep Tag #3 @ 10355ft. Plug #3 gone 10min. Plug 5bbl gel sweep Tag plug #4 @10827ft Plug #4 gone 18min. Plug 20bbl gel sweep Tag plug #5 @ 11071ft short trip to 7800ft. RIH Tag plug #5@ 11071ft plug 5 gone, 5 bbl sweep (24 minutes) 11312 tag plug 6 plug 6 gone! 5 bbl sweep (11 minutes) 11502 tag plug 7 plug 7 gone, 20 bbl sweep (13 minutes) 11764 tag plug 8, SIT 10135 pulling trash~ithout motor action, rih 1 oo· 10135 pump 10 bbl sweep 9996 hole sUII trashy. pump 80 vis sweep 7200 top of SlT eire bottoms up from here rih 10758 tag plug 8 plug 8 gone, 5 bbl sweep (6 minutes) 12045 tag plug 9 plug 9 gone, 10 bbl sweef? {15 minutes) 12319 tag plug 10 plug 10 gone, 20 bbl sweep (15 minutes) tag plug 11, S/T AOL relieve Heath RIH Tag plug #11 @ 12600ft Plug #11 gone 24m in plug bbl gel sweep 24 minutes Tag plug #12 @ 13017ft Plug #12 gone 6min plug 5bbl gel sweep 6 minutes Believe we tagged #13 changed rates, milling methods 3X gel sweeps no progress Company Man Cal S. wants to POOH check BHA/mill 4hrs w no progress trying different milling methods, CP rates, coil tubing speeds, may be spinning on plug slips or mill worn on RDV. POOH At surface MU coH co,nnector pull test 25K then 20K Test BHA Heath aol, looked at bit and job logs and WBD and determined we had been milling on the initiator sleeve, had conference call with Cal & Lex & all agreed drill out was complete & we would go ahead & run the packet rih with packer, providing coil connevtor and back pressure valve ooh leave location 15 Composite Material Slips • Materials used in construction conducive to a wide range of • Traditional Gray Cast iron slips. environments. • No need for metallic material to be used in mandrel for burst/ collapse reinforcement. • Ability to thread Bridging Pin / Caged Ball Adapter directly into mandrel ID w/o utilizing brass/aluminum. • High Thread Strength. • No need for pins/bond to strengthen the bottom mandrel / shoe connection. 16 • Heat treated to wicker depth only. • 50-60 HRC with a case depth of .040-.050". • Holes drilled entirely through slip segments, which allows segment to break into smaller pieces during millout. • Sets securely in up to P110 casing. • Cast Segmented Slips also available. Express Series Setting Equipment Express Series Plugs are set using a rugged and durable universal Setting Sleeve and Shear Sleeve Adapter. Setting kits are designed to be run on any wireline setting tool or tubing run hydraulic setting tool with either Baker #10, Baker #20 or 3 ½" G.O. connections. • The Shear Sleeve Adapter is placed over the top of the plug and secured using steel shear screws while the Setting Sleeve is installed over the Shear Adapter. • The Setting Assembly utilizes an Adjuster Nut that mates the directly to the setting tool. The Setting Sleeve is allowed to be threaded upwards past the Adjuster Nut and secured onto the setting tool. Non-Preset Feature • Each Setting Sleeve has drilled and tapped holes (Fig. A) that when made up on the Setting Tool, line up with the shear groove on the O.D. of the Shear Adapter (Fig. B). • Two provided Brass screws (1,800 lbs shear ea.), can be installed in the holes on the Setting Sleeve until they bottom out in the shear groove on the Shear Adapter. • This feature prohibits the Setting Sleeve from moving downward and applying force on the plug, which can result in a plug pre-set, as the two brass shear screws have to be sheared before the Sleeve can begin downward motion. B A Setting Shear Pins • Steel setting pins with a shear value of 4,600# min – 4,700# max, are used to set plugs sized 4 ½" and larger. 4 ½" – 6 pins 5" – 7 pins 5 ½" – 7 pins 7" - 10 pins • Brass setting pins with a shear value of 1200# are used for 3 ½" (5 pins) and smaller sized plugs. • Setting pins are used so that the ID is left open and available for plug conversion. 17 1 2 3 5 4 BAKER No. 05 E-4 W.L.P.S.A. Baker No. 05 Setting Adapter Kit Tool Size - 3 ½" x 9.3-10.2# Wireline Adapter Kit EWST-3500 18 Item Qty Description Part Number 1 1 Adjuster Bushing EWST-3500-BK05-185 2 2 Socket Set Screw ¼-20 X ¼ lg 3 1 Setting Sleeve EWST-3500-BK05-180 4 1 Shear Sleeve EWST-3500-BK05-175 5 5 Shear Screw ECFP-3500-080 1 3 2 4 5 6 7 8 9 No. 10 E-4 W.L.P.S.A. Baker No. 10 Setting Adapter Kit Tool Size Setting Kit 4 ½" x 15.1-17.1# 4 ½" x 9.5-15.1# 5" X 18-23.2# 5 ½" x 13-23# EWST-4400 EWST-4500 EWST-5100 EWST-5500 Item Qty Description Part Number Part Number Part Number Part Number 1 1 Adjuster Bushing EWST-BK10-179 EWST-BK10-179 EWST-BK10-179 EWST-BK10-205 2 1 Socket Set Screw ¼-20 X 3/16 lg ¼-20 X 3/16 lg ¼-20 X 3/16 LG ¼-20 X .31 lg 3 2 Socket Set Screw ¼-20 x .31 lg ¼-20 x .31 lg 3/8-24 X .31 LG 3/8-16 x .31 lg 4 1 Setting Sleeve EWST-44BK10-181 EWST-BK10-181 EWST-5BK10-181 EWST-BK20-205 5 1 Extension Rod NOT REQUIRED NOT REQUIRED NOT REQUIRED EWST-BK10-207 6 1 Lock Spring ECFP-BK10-000 ECFP-BK10-000 ECFP-BK10-000 ECFP-BK10-000 7 2 Non-Preset Screw 054-5360-123 054-5360-123 054-5360-123 054-5360-123 8 1 Shear Sleeve EWST-44BK10-180 EWST-BK10-180 EWST-5BK10-180 EWST-BK10-203 9 Noted Shear Screw ECFP-5500-028 (6) ECFP-5500-028 (6) ECFP-5500-028 (7) ECFP-5500-028 (7) 19 1 2 3 4 5 6 7 8 9 10 BAKER No. 20 E-4 W .L.P .S.A. 20 Tool Size 5 ½" x 13-23# 7" x 23-32# & 7" x 17-23# Setting Kit EWST-5500 EWST-7000 Item Qty Description Part Number Part Number 1 1 Socket Set Screw ¼-20 x 3/16 lg ¼-20 x 3/16 lg 2 2 Socket Set Screw 3/8-16 x .31 lg 3/8-16 x .31 lg 3 1 Adjuster Bushing EWST-BK20-208 EWST-BK20-218 4 1 Socket Set Screw 3/8-16 x .38 lg 3/8-16 x .38 lg 5 1 Setting Sleeve EWST-BK20-205 EWST-BK20-220 6 1 Adjuster Sub 0660020035 0660020035 7 1 Lock Spring ECFP-BK20-000 ECFP-BK20-000 8 4 Non-Preset Screw 054-5360-123 054-5360-123 9 1 Shear Sleeve EWST-BK20-202 EWST-BK20-215 10 Noted Shear Screw ECFP-5500-028 (7) ECFP-5500-028 (10) 1 2 3 4 5 6 7 8 No. 10 E-4 W .L.P .S.A. “GO” 3625 Setting Adapter Kit Tool Size 3 ½" x 9.3-10.2# 4 ½" X 9.513.5# 5" X 18.23.2# 5 ½" X 13-23# 7" X 23-32# & 7" X 17-23# Setting Kit EWST-3500 EWST-4500 EWST-5100 EWST-5500 EWST-7000 Item Qty Description Part Number Part Number Part Number Part Number Part Number 1 Noted Socket Set Screw ¼-20 x 5/16 lg (1) ¼-20 x 5/16 lg (1) ¼ x 5/16 lg ¼-20 x 3/16 lg (2) ¼-20 x .38 lg (2) 2 2 Socket Set Screw 3/8-16 x 5/16 lg 3/8-16 x 5/16 lg 3/8-16 x 5/16 lg 3/8-16 x 5/16 lg 3/8-16 x 5/16 lg 3 1 Adjuster Bushing EWST-3500-1687-185 Not Required NOT REQUIRED EWST-3625-189 EWST-7-3625-222 4 1 Setting Sleeve EWST-3500-1687-180 EWST-3625-181 EWST-5HW-3625-181 EWST-3625-186 EWST-BK20-220 5 1 Jam Nut 052-5303-019 052-5303-019 052-5303-019 052-5303-019 052-5303-019 6 1 Shear Sleeve EWST-3500-1687-175 EWST-3625-190 EWST-3625-180 EWST-7-3625-224 7 2 Non-Preset Screw 054-5360-123 054-5360-123 054-5360-123 054-5360-123 054-5360-123 8 Noted Shear Screw ECFP-3500-080(5) ECFP-5500-028(6) ECFP-5500-028(7) ECFP-5500-028(7) ECFP-5500-028(10) 21 Plug / Setting Tool Assembly Plug / Setting Tool Inspection used on the 4.5). Make sure pins are made up tight into the plug • Confirm plug is appropriate and qualified for the particular casing and Shear Sleeve Adapter. weight and ID of the well. • Confirm that the correct setting tool and setting equipment are being utilized and all is in working order. Setting tools should • Fix appropriate Tension Spring or “GO” Lock Nut onto the Shear Sleeve Adapter. • Thread the Shear Sleeve Adapter into the Setting Tool (or Adjuster be cleaned and maintained according to the manufacturers Sub/Donkey Tail) of the Setting Tool until approximately 3 threads instructions. When in doubt, do not use a setting tool with are left. questionable working order. • Use only ProDrill setting kits. Do not attempt to set Express Series plugs using another manufacturers setting kits. • Visually inspect the composite plug to verify that all components • At this point, the Setting Sleeve should be approximately .100.200 from the top of the top slip of the plug. Install and secure the Setting Sleeve into the OD groove of the Shear Sleeve Adapter using two of the provided Brass Shear Screws. It is recommended are in working order and show no signs of cracks, punctures, or that two of these screws are used. Shear value of each screw is other damage. approximately 1,800 lbs. • If there is a gap in the Setting Tool between the Lock Ring and the Plug / Setting Tool Makeup Crosslink Sleeve, thread the Setting Sleeve down turning to the left • Thread the Sleeve Adjuster Nut, which is already made up and until the gap closes. secured onto the Setting Sleeve, onto the Crosslink (Bottom) of the Setting Tool. Using the pre-installed ¼-20 Set Screw, secure the Sleeve Adjuster Nut onto the Setting Tool. • If using a #20 Setting Tool, thread the Adjuster Sub (Donkey Tail) onto the Setting Mandrel of the Setting Tool if there is not one already installed. If using #10 or 3.5 “GO”, proceed to the next step. • Place the appropriate Shear Sleeve Adapter onto the plug and secure with the provided shear pins (7 pins used on the 5.5 / 6 pins 22 • Plug is ready to run. Running in Hole • Casing should be cemented and removed of scale by use of a casing scraper prior to running composite plugs. • A gauge ring should be utilized to confirm that the casing ID is large enough for the appropriate plug to be run. • Do not rest the tool string weight on the plug and make sure plug is aligned with the setting tool during installation. • Use standard or fast burning power charges.Slow burning power charges are not recommended. • Thoroughly flush the wellbore of sand at the appropriate setting depth and wait three to four hours after fracturing before running the next plug. • Never set a plug in a casing collar. • Do not set plugs with 25 feet of the target perforation zone. Running in Hole – Wireline in a Vertical Well • A running speed of 150-175 FPM or less is recommended until the fluid level is reached to avoid risk of pre-setting the plug when reaching fluid or sand. • After the fluid level has been reached, a running speed of 250300 FPM or less is recommended. Once the setting tool has been fired, wait 60-90 seconds to ensure that the plug is fully set. • Note: If plug is configured as a Ball Drop Frac Plug, resting the Running in Hole – Wireline in a Horizontal Well • A running speed of 150-175 FPM or less is recommended until the fluid level is reached to avoid risk of pre-setting the plug when reaching fluid or sand. • After the fluid level has been reached, a running speed of 250300 FPM or less is recommended. • If extreme areas of deviation, restrictions, or areas of concern are present, adjust run speed accordingly. • While approaching the kick off point, decrease the run speed to approximately 125-150 FPM. • Begin pumping fluid at 1-2 barrels per minute. • As the deviation become greater, gradually increase the fluid pump rate at no more than 2 BPM increments. • It is recommended to not exceed a pump rate of 15 BPM or run speed of 300 FPM. • At approximately 250-300ft from the desired set depth, slow run speed to approximately 100 FPM in order to release slack from the line. • Once the setting tool has been fired, wait 60-90 seconds to ensure that the plug is fully set. • Note: If plug is configured as a Ball Drop Frac Plug, resting the bottom hole assembly or tagging the plug may cause damage to bottom hole assembly or tagging the plug may cause damage to the ball seat at the top of the plug. the ball seat at the top of the plug. 23 Plug Removal: • Bits/Mills - Many styles of bits and mills can be used to remove the ProDrill plug. The most common are the 5 Blade Junk Mill, Butterfly Mill, Flat Bottom Mill, and the Tri-Cone Rock Bit. The flat bottom mill will provide the smallest returns but at a cost of a bit trip after approximately 10-12 plugs. The other bits/mills mentioned will provide more longevity. • The mill/bit should have a minimum shank length of four inches with a fishable diameter within the tubing being used. For a bladed junk mill, an inward tapered mill will reduce the possibility of damaging the casing and it should have one blade that extends across the face of the mill approximately 70% to minimize coring of the plug. • Recommended O.D. of bit/mill is at least 90% of the casing ID Using a smaller O.D. will increase the possibility of sticking pipe or coring the plug. choice in most cases. If drilling under balance, ensure a float is installed in the bit sub. • Use of drill collars for weight and centralization is recommended. • Run in hole with the drill assembly to a depth approximately 30-35’ above the plug, pick up the power swivel and make up circulating equipment. If conventional circulation and under balance method are used, ensure a screen is installed in the pump line to prevent debris from being pumped down and clogging up the bit. Establish circulation to ensure fluid or foam/air has been pumped to the bit before moving down to the plug. • Start Rotation with the power swivel, and make sure torque is properly set to the recommend range of 50-150 RPM. If operating in deviated wells, a lower RPM range of 60-80 RPM’s may be all that is available due to increased drag and torque. With safety in mind, rotate the pipe as fast as torque and weight limits will allow. • Once rotation and circulation are established, slowly lower tubing to contact the plug. A pump rate of .5 - 3bbl/m is recommended 24 Jointed Pipe General Practices if returns are possible. A junk basket is recommended to • Make up the proper size bit or mill on a bit release sub or if circulation cannot be achieved. Maintain approximately 1000 prevent large cuttings from settling on the plug during drilling standard bit sub. A medium tooth roller bearing bit that is at least to 4000-lb. weight on bit. Observe weight indicator and torque 92-95% of casing drift diameter provides the quickest drill time gauge and adjust weight on bit according to drill off. If swivel in standard reverse units or snubbing operations and is the bit of stalls, pick up on tubing string to allow the tubing to rotate freely, lower the tubing and engage the plug again. Repeat these steps motor size. The weight on bit should only be increased if rotation until the composite plug is drilled and tubing can be lowered starts to occur. without turning the swivel. Drill rates will vary according to weight on bit, circulation rates, velocity around the bit, or bit tracking. If torque reading indicates bit tracking, raising and lowering the pipe while rotating will change the cutting area. • When the bit reaches the rubber elements a decrease in weight • The flow rate should be between 2–3 bbl./min depending on motor size. • Establish flow rate before making contact with the plug. Start milling using minimum to mid-range flow rate. Higher flow rates tend to hydraulically lift the milling assembly off of the plug. More on bit may be needed to reduce excessive torque. This will allow weight on bit can correct this. The weight on bit will fluctuate so the element to be drilled into smaller pieces instead of tearing the try to keep differential pressure reading constant. rubber into large pieces. • If drilling multiple plugs, allow circulations of at least one tubing • If plug stops milling at a constant rate, pick up off of plug and set back down weight to establish new cutting pattern on plug. volume after drill out of each plug before beginning drill out of Proceed slowly through the first twelve inches to allow the next plug. This will allow bit clean up and ensure fluid mixture is pressure to equalize. There may be a drastic difference in pressure at the bit before continuing drilling operations. After drill up of above and below the plug. a plug, move up hole 30-100’ and use a gel sweep to circulate debris from bit and wellbore. • When drilling multiple plugs, circulate at least the volume of tubing between plugs to allow clean up and establish good fluid at bit before drilling next plug. Coiled Tubing General Practices • Motor RPM should be in the 250–600 range based on motor size although the motor company should be consulted on topics regarding motor speed. • Weight on bit should be between 1500–3000lbs depending on 25 Flow Control Completion Products • Tubing Mounted Flow Control Equipment is made up and run in conjunction with the completion packer system. The equipment is part of the completion string and is considered packer system accessories. • Tubing Mounted Flow Control Equipment serves two purposes: – A receptacle for Flow Control accessories – To provide communication between the tubing and casing zone • To provide communication between the tubing and casing zone • Specialized alloys and premium threads available upon request. • Flow Control Equipment Available: – Landing Nipples – Circulating Sleeves – T-2 On/Off Tools – Pump Out Plugs – Wireline Re-Entry Guides – Bypass Blanking Plugs – Equalizing Check Valves – Crossovers – Shear Out Safety Joints – Wireline Service Tools Our goal is to become the leading provider of mission critical oilfield products and related services in terms of customer satisfaction, safety and financial performance. Our experienced management team and employees are dedicated to solving our customers’ problems. We invest in long term relationships and cooperate on product development with our clients, we consider them our partners. OUR CORE VALUES Integrity: In everything we do, in every interaction, both internally and externally, we strive to operate with the upmost integrity and mutual respect. Long-term view: We are building our company for the long-term, a company that we can be proud of. Open communication: We believe partnerships with our customers and co-workers must be based on trust, professionalism and transparency. Customer focused: Our products enhance our customer’s performance and we listen to their needs and work with them to solve their challenges. Good place to work: We are committed to creating a workplace that fosters innovation, teamwork and pride. Every team member is integral to our success and is treated equally and fairly. No one gets hurt: The safety of our employees and customers is our first priority coupled with a healthy respect for the environment. Downhole Technologies Headquarters 10344 Sam Houston Park Drive, Suite 300 Houston, TX 77064 713.351.7900 f-e-t.com / Downhole DWN 1008 27