Study and Field Trials on Dissolvable Frac Plugs for Slightly Deformed Casing Horizontal Well Volume Fracturing

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 m³ 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.