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$Image of well heads completing a frac, utilizing downhole completions tools including Frac plugs$

Deformed Casing Pressure Test

PurpleSeal™ frac plugs proved to anchor in deformed casing, meeting 5% ovality and 10,000 psi treatment pressure requirements.

Challenge

Oval casing is a proxy for deformed casing. There are many mechanisms that can contribute to casing deformation and not all are well understood. Operators have some risk mitigation techniques but most operators expect casing deformation at some frequency. There is a need for slimmer frac plugs that pass through deformed casing sections and even anchor and seal in deformed casing.

Repeat Precision developed the 3.40” and 4.25” PurpleSeal frac plug sizes for these needs. They are slimmer tools which can be RIH faster at the same risk level as their larger brothers, the 3.60” and 4.38” PurpleSeal frac plugs. These slim plugs are proven; they’ve been called out to location to address many wells with tight spots. A question was, can they anchor in deformed casing?

A warehouse where a deformed casing pressure test took place.

Solution

We developed and ran a test with deformed casing where a load was applied to the casing throughout the test much as it would be downhole. The frac plug was set in the deformed casing, and a pressure test was completed while the load was continuously applied and monitored.

The 360 PSC was tested in both 4.5”13.5 ppf and 15.1 ppf casing. The oval casing tests were performed twice in each size case, once at 2.5% ovality and once at 5% ovality.

In all four test cases, the PSC plugs held 10,000 psi for one hour in deformed casing. Upon post-test inspection, the 2.5% ovality tests revealed little difference from typical tests. Slips and cones from 5% ovality tests had evidence of uneven loading. The peak pressure capability of the plug was compromised; however, PurpleSeal™ plugs still met the max treatment pressure requirement of 10,000 psi.

Pressure Level: 10 KSI
Duration: 1 Hour
Ovality Measurements: 2.5% and 5.0%
‍Setting Force: 25,000 lbs

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Products

The PurpleSeal™ PS-C all composite plug with ceramic buttons, zero metal content, and interlocking components for consistently fast drill-out times.

Features

10,000 PSI
Lightweight materials for industry-leading drill-out performance
Patented rubber element backup to prevent casing erosion damage
Tested in oval casing with exceptional conformity (10,000 psi tested)
Ceramic buttons
Pump-down fin included with every plug for more fluid savings
Anti-preset features in the plug and wireline adapter kit
No run-in-hole speed limits when pumping
Ball-on-seat capable
Top set

Benefits

Better drill-outs and a lower debris profile than any other product on the market
Successful plug deployment with high run-in speeds, less water, and fewer pre-sets
Impeccable isolation with over one inch of seal engagement with casing
Dedicated customer service with free on-location dispatch within four hours in any major basin
Affordable pricing with no hidden costs for mileage, service, or waste disposal

CASE STUDY: PS-C OVAL CASING TEST

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