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Composite Frac Plug
The Ultron Composite Frac Plug uses a new high-strength composite material that is easily drilled, and
the drilling chipping is easily retrieved.
The slip uses composite material, with a unique design that is easy for drilling and milling, which could reduce the operation time and extra cost for our customer.
The combined cones-shoulder protection structure design can ensure the sealing performance of the rubber.
Description
China Vigor Drilling Oil Tools And Equipment Co., Ltd. is one of the most professional manufacturers and suppliers of composite frac plug in China, featured by competitive price and fast delivery. Welcome to buy high quality composite frac plug in stock here from our factory.
Features
● Available in 3-1/2",4", 4-1/2", 5", 5-1/2", 7" & 9-5/8" .
● Consistent drill times of 5-8 minutes or less.
● Ultron™ composite plugs are constructed from molded or machined composites, with composite slips, ensuring fast drilling and high reliability.
● The setting sleeve and shear adapter are designed to run on any wireline setting tool or tubing-run hydraulic setting tool, with Baker #10, and Baker #20 connections.
● Can be drilled out using conventional rigid tubing or coiled tubing.
Technical Parameters
|
Casing |
Bridge Plug Technical Parameter |
||||||||
|
(In.) |
Weight (lbs/ft) |
O.D. (mm) |
I.D. (mm) |
Length (mm) |
Setting Tool |
Setting Force (lbs) |
Temp. Rating (℉) |
Pressure Rating (psi) |
NO. |
|
3-1/2 |
7.7-9.2 |
70 |
20 |
500 |
Baker #5 |
8,800 |
250/300 |
10,000 |
UCFP-3500-V010 |
|
4 |
9.5-10.7 |
80 |
20 |
500 |
Baker #10 |
26,000 |
250/300 |
10,000 |
UCFP-4000-V020 |
|
4-1/2 |
11.6-13.5 |
89 |
25 |
500 |
Baker #10 |
26,000 |
250/300 |
10,000 |
UCFP-4500-V030 |
|
5 |
18.0-21.4 |
95 |
30 |
550 |
Baker #10 |
26,000 |
250/300 |
10,000 |
UCFP-5000-V040 |
|
5-1/2 |
17.0-23.0 |
110 |
33 |
600 |
Baker #20 |
38,000 |
250/300 |
10,000 |
UCFP-5500-V050 |
|
5-1/2 |
17.0-23.0 |
110 |
50 |
600 |
Baker #20 |
38,000 |
250/300 |
8,000 |
UCFP-5500-V051 |
|
6-5/8 |
20.0-24.0 |
140 |
50 |
600 |
Baker #20 |
38,000 |
250/300 |
10,000 |
UCFP-6625-V060 |
|
7 |
23.0-32.0 |
145 |
50 |
740 |
Baker #20 |
53,000 |
250/300 |
10,000 |
UCFP-7000-V070 |
|
9-5/8 |
36.0-58.4 |
206 |
114 |
760 |
Baker #20 |
53,000 |
250/300 |
7,000 |
UCFP-9625-V110 |
Benefits and Applications
Benefits
● Withstands extreme pressures and temperatures
● Strong gripping force without slippage
● Composite construction mills out rapidly
● Minimal debris for easy cleanup
● Meets or exceeds API/ISO standards
● Enables faster multistage operations
Applications
● Multistage fracturing in horizontal wells
● Plug-and-perf operations
● Zonal isolation for production
● Horizontal, deviated and vertical wellbores
● High pressure/high temperature environments
Working Principles
The composite frac plug is run into the wellbore and actuated via hydraulic pressure or mechanical forces. This compresses the slip and cone assembly, forcing the slips outward to bite into the casing wall. The elastomeric seal element is also compressed to create a tight seal.
Differential pressure across the plug further enhances the gripping force and sealing performance. The proprietary backup systems prevent extrusion or by-pass. After fracturing, the plugs are milled out from top to bottom using a rotational milling BHA. The composite materials quickly disintegrate into small cuttings that can circulate easily out of the hole.
Construction & Key Components
The composite frac plug assembly is built from a named set of components. The bill of materials below is provided to support field identification and troubleshooting:
| Component | Function |
|---|---|
| Guide shoe | Leads and centers the plug during run-in. |
| Center tube | Main load path; connects to setting tool via shear adapter. |
| Sealing element (rubber) | Compresses against casing wall to form the seal. |
| Upper / lower slips | Composite slips bite into casing to anchor the plug. |
| Upper / lower cones | Convert setting force into outward slip movement. |
| Upper / lower backup shoulders | Protect rubber from extrusion under HPHT. |
| Shear pins | Release the setting tool once target force is reached. |
| Ball / plug (optional) | Closes the center bore per plug type. |
Composite Bridge Plug Types (Deployment Options)
Vigor supplies the composite frac plug in three configurations to match different completion and frac sequences:
1. Blind (Pre-Plugged) Bridge Plug
The center bore is sealed with a plug on surface before running. After setting, the well can be fractured directly - eliminating the ball-drop and pumping steps, saving rig time and operational cost.
2. Ball-Drop Bridge Plug
The center bore is left open on surface. After setting, the wellbore remains flowing and accessible for logging or testing. The ball is dropped only when fracturing is required.
3. Ball-Cage Bridge Plug
The sealing ball is pre-fixed in the ball seat above the center tube on surface. After setting, fracturing can begin without a separate ball drop - reducing the volume of ball-drop fluid required.
| Type | Center Bore on Surface | Ball Drop Required? | Best For |
|---|---|---|---|
| Blind / Pre-Plugged | Sealed | No | Fast direct frac, cost saving |
| Ball-Drop | Open | Yes (later) | Logging / testing before frac |
| Ball-Cage | Ball pre-seated | No | Less ball-drop fluid |
Features of Composite materials
High strength and stiffness: Composite materials have a very high strength-to-weight ratio and stiffness-to-weight ratio, enabling them to withstand high pressure and temperature.
Corrosion resistance: Composite materials are resistant to corrosion, making them suitable for harsh environments such as oil and gas wells.
Lightweight: Composite materials are lighter than traditional metallic materials, making them easier to transport and install.
Tailorability: Composite materials can be tailored to meet the specific dimensional, shape, and performance requirements of a particular application.
Electrical insulation: Certain composite materials possess electrical insulation properties, making them suitable for applications where electrical insulation is required.
Running & Setting Procedure
- Pre-job preparation: Circulate/wash the wellbore, drift and scrape as required, and plan the setting depth - always avoid casing collars.
- Connect the hydraulic setting tool to the tubing and run the plug to depth.
- Apply setting force through the tubing. When the force reaches the shear-pin rating, the pins break and the setting tool releases, completing the plug disconnect.
- Pull out of hole, then determine (by plug type) whether a ball must be dropped from surface.
Drill-Out / Milling Procedure
After fracturing, the composite plug is milled from top to bottom using a rotational milling BHA. Recommended field parameters:
| Parameter | Recommendation |
|---|---|
| Bit | New, short-tooth, medium-hardness bit. |
| Rotary speed | 80 rpm (up to 120 rpm if needed). |
| Weight on bit (initial) | 5,000–7,000 lbs until the top of the center-tube OD is milled off (≈7 in / 180 mm for 4-1/2"–7" plugs; ≈10 in / 254 mm for 7-5/8" and larger). |
| Weight on bit (increased) | Add 2,000–3,000 lbs per inch of bit diameter. |
| Drill collars | Rotate intermittently - min. 8 collars (4-1/2" & 5-1/2"), min. 12 (7" and larger). Vary RPM and WOB; use one or more junk baskets during circulation. |
Caution: Monitor pump pressure closely while milling. When the bit reaches the rubber element, pressure can rise suddenly - stop the pump, hold the string weight, work the pipe slightly, and resume only after pressure returns to normal.
4-1/2'' Utron Composite Bridge Plug Setting Test
FAQ
Q: How does the plug achieve a reliable seal?
A: The elastomeric element provides a metal-to-metal seal when compressed. Backup systems prevent extrusion or by-pass even at 10,000+ psi pressures.
Q: How long does it take to mill out the plugs?
A: Our low-profile design typically mills out in 5-8 minutes, around 4x faster than cast iron or alloy plugs. This provides significant time savings.
Q: Are these suitable for horizontal wellbores?
A: Yes, our composite plugs are commonly used for multistage fracturing in horizontal wells. The lightweight design reduces friction.
Q: What is the difference between a blind, ball-drop and ball-cage frac plug?
A: A blind plug has its center bore sealed on surface and is fractured directly; a ball-drop plug keeps the bore open for logging then drops a ball later; a ball-cage plug has the ball pre-seated so no separate ball drop is needed.
Q: How should the plug be stored before deployment?
A: Store indoors at ~20°C / 50% RH, keep packaging intact, coat metal parts with light oil, wrap rubber in oil paper, and follow FIFO. Rubber validity is about 2 years under controlled conditions.
Delivered Photos
The Ultron Composite Frac Plug
Vigor is a leading manufacturer of specialized products for oil and gas production including composite frac plug. We have an extensive inventory and can fulfill orders quickly. Our quality management system ensures every plug meets stringent standards. Please contact us if you need any additional details or want to discuss how our products can improve efficiency on your plug-and-play project. We look forward to serving your downhole isolation needs.
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