In view of the need
for slightly deformed casing horizontal well
fracturing, a new dissolvable frac plug has been designed using mechanical
and material methods. The results of simulation analysis, laboratory
research, and field test verification show that: (1) the integral
half-split inlaid tooth slip and implicit-shaped single sealing element
are adopted. Under the same pressure resistance index, the outer diameter
and the total length of the frac plug are small, the inner diameter
is big, and the pressure resistance downhole passing performance are
better. (2) Using dissolvable magnesium-based powder, hydrogenated
butadiene-acrylonitrile rubber, fluororubber polyglycolic acid, and
the cellulose fiber and coating process, the solubility of the frac
plug is observed to be more reliable. (3) Using the structural modular
design, the frac plug has outstanding advantages in terms of on-site
installation, preventing early seat sealing, self-separation after
release, less dissolvable matter, and so on. (4) The finite element
simulation and physical simulation experiments show that 121.36 mm
ID casing with the frac plug can tolerate deformation in the range
of 15 mm, which meets the needs for the casing usage. The temperature
increases from 60 to 98 °C, and the maximum sustainable pressure
differential decreases from 7.6 to 11.2 h at 70 MPa without any leakage.
The frac plug can be completely dissolved within 300 h, and the final
size of the residual solid is less than 0.3 mm. (5) In field trials
of eight wells, through the minimum set of change inner diameter of
107 mm, the maximum wellhead fracturing pressure is 83.9 MPa in the
formation, with the temperature ranging from 36 to 110 °C, and
the plug can be completely self-dissolved in 16 days (the shortest
time that has been found). After the fracturing operation with this
dissolvable frac plug, the average daily oil production is maintained
as high as 10.45 t with 22,000 m
3
gas production. A new
dissolvable frac plug tool solves the problem of continuous fracturing
in slightly casing variable wells, restores the full bore of the wellbore
after staged fracturing, and realizes the production of oil and gas
wells without drilling plug and the smooth implementation of follow-up
measures. It has a wider application range, higher efficiency, safety,
and economy. It is of great significance for industrialized staged
fracturing of unconventional oil and gas horizontal wells and platform
wells.