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Frac plug drill out success in long lateral

Repeat Precision drilled out 262 PurpleSeal™ PS-C composite frac plugs in 154 hours with impeccable isolation.


In Pennsylvania’s Marcellus Basin, a major operator drilled a three-mile lateral constructed with 6” 24# production casing measuring 23,938 ft (MD) and a lateral length of 15,672 ft. The greatest challenge that completions teams face when dealing with long lateral sections is the plug drill-out. The plug selection for this situation was critical for obtaining a clean and effortless drill-out.

An equally important aspect of an operation this extreme is protecting vital bit, sub and motor components to ensure the BHA can withstand the harsh trip through 262 composite frac plugs. To make the project that much more challenging, the operator, Repeat Precision, Taurex Drill Bits, and Workover Solutions devised a plan that would lead to an operational first in the completions space: a single-trip drill-out of 262 frac plugs.

Taurex’s JZ completion bit after drilling out 262 PurpleSeal™ frac plugs.


Once the plug selection and stage spacing were finalized in the completion program, Workover Solutions proposed using patented BitSavR technology, WOS-engineered an manufactured POWR Motors, and WOS-developed AV sub. Taurex selected one of their patented premium line JZ completions bits. These technologies, paired with the PurpleSeal™ composite frac plug, created the optimal scenario to achieve our goal of a single-trip drill-out.

The drill-out consisted of using a Deep Well snubbing unit, patented WOS BitSavR technology, WOS engineered and manufactured POWR Motors, and WOS-developed AV sub, and a Taurex JZ completion bit. The entire drill-out was completed in a single trip lasting approximately 6.5 days.

As result of a controlled WOB approach, no short trips and minimal motor stalls were reported. After the job, Taurex utilized their patented BitVision™ technology to verify that the bit maintained a 24% effective cutting structure with all cones and bearings intact. This project proved to be a tremendous success and was repeated three more times in the subsequent wells on the same pad, totaling 261, 259, and 255 stages each.

  • Number of plugs: 262 PurpleSeal™ PS-C all-composite plugs with ceramic buttons
  • Total trip time: Less than 154 hours
  • PurpleSeal™ plug drill-out time: 16.9 min average
  • PurpleSeal™ plug wash time: 18.4 min average
  • Lateral length: 15,672 ft
  • Casing: 6-in., 24 lb/ft
  • Drill bit: Taurex’s JZ completion bit

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  • 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


  • 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
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CASE STUDY: Frac plug drill out success in long lateral
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