Fracturing tools

Technical Specifications – Fracturing Tools

Composite Frac Plug (Standard, API 11D1)

Parameter	Specification
Casing Sizes	4‑1/2″, 5‑1/2″, 7″, 7‑5/8″, 9‑5/8″
Max Differential Pressure	10,000 PSI (69 MPa)
Max Temperature	150°C (302°F)
Seal Element Material	High‑temperature nitrile / HNBR (optional: FKM for aggressive fluids)
Slip Material	Composite with carbide‑grit buttons or cast iron (optional)
Ball Seat Size Options	0.75″ to 1.75″ (standard) or burst disk
Drill‑out Method	PDC bit, mill, or coil tubing
Drill‑out Time (typical)	5–15 minutes per plug
Compliance	API 11D1 (Packers and Bridge Plugs)

Cast Iron Bridge Plug (Permanent)

Parameter	Specification
Casing Sizes	4‑1/2″ to 9‑5/8″
Max Differential Pressure	10,000 PSI (higher on request)
Max Temperature	150°C (302°F)
Body Material	Ductile cast iron
Seal Element	HNBR / FKM (optional for CO₂/H₂S)
Setting Method	Hydraulic or mechanical (specify)
Drill‑out	PDC or roller cone bit (slower than composite)

Dissolvable Frac Plug & Ball

Parameter	Dissolvable Plug	Dissolvable Ball
Casing Sizes	4‑1/2″ – 7″	N/A (for use with composite seats)
Max Pressure	10,000 PSI	10,000 PSI
Max Temperature	120°C (250°F) – standard; 150°C available	120°C standard
Dissolution Time	3 – 21 days (field‑adjustable by alloy formulation)	3 – 14 days
Dissolution Trigger	Produced brine / frac fluid / temperature	Same
Residue	Soft, fine particles (non‑damaging to pumps or screens)	Same
Drill‑out Required?	No	No

Hydraulic Setting Tool (for Frac Plugs)

Parameter	Specification
Setting Pressure	1,500 – 3,000 PSI differential
Maximum Pull/Push	40,000 lbs (180 kN)
Tool OD	3‑1/8″ to 5″ (fits inside corresponding casing)
Connection	2‑3/8″ or 2‑7/8″ EUE / PAC (custom available)
Compatibility	Works with most industry‑standard frac plugs

Product Types – Fracturing Tools Lineup

1. Composite Frac Plug (Standard)

Best for: Multi‑stage plug‑and‑perf fracturing in horizontal shale and tight gas wells.

Features: Fast drill‑out, high‑pressure rating, anti‑rotation buttons, compatible with wireline or coil tubing conveyance. Available with burst disk (saves a ball run) or ball seat.

Lead time: 2–3 weeks for standard sizes. Large volume orders (500+ pieces) – 4–6 weeks.

2. Composite Frac Plug – High Expansion (for damaged or worn casing)

Best for: Wells with corrosion, wear, or irregular casing ID.

Expansion range: Up to 20% over nominal casing ID. Seals in casing that standard plugs would pass through.

3. Cast Iron Bridge Plug

Best for: Permanent abandonment, plug‑and‑abandon, zone isolation (lower completion), and plug‑back operations.

Features: Metal‑to‑metal sealing, millable, high temperature rating, compatible with hydraulic or mechanical setting tools.

4. Dissolvable Frac Plug

Best for: Operators who want to eliminate drill‑out costs and rig time.

How it works: Set the plug like a standard composite plug. After fracturing, the plug dissolves in produced brine or residual frac fluid. No intervention required. The well goes on production without a plug drill‑out.

Limitation: Requires specific brine chemistry and temperature for predictable dissolution. We provide dissolution curves based on your well data.

5. Dissolvable Frac Ball

Best for: Use with composite plugs that have standard ball seats. Allows you to eliminate the drill‑out for the ball itself. The composite plug still requires drill‑out (unless you use a full dissolvable plug).

Cost‑saving: Less than full dissolvable plug, but only addresses the ball, not the plug body.

6. Hydraulic & Mechanical Setting Tools

• Hydraulic setting tool – for use with wireline or coil tubing. Activated by pump pressure across a shear disc or piston.

• Mechanical setting tool – for use on workstring (tubing or drill pipe). Activated by tension, compression, or rotation.

We also supply setting tool adapter kits to fit competitor plugs (Baker, Halliburton, Weatherford, etc.).

7. Fracturing Packers (Retrievable & Permanent)

Type	Set Method	Release	Application
Single‑grip retrievable	Hydraulic or mechanical	Straight pull	Test‑treat‑test, selective isolation
Double‑grip retrievable	Hydraulic or mechanical	Rotation or pull	High‑rate fracturing in deviated wells
Permanent packer	Hydraulic	Drill‑out	Abandonment, production packer

Pressure rating: Up to 10,000 PSI. Temperature: Up to 150°C.

8. Frac Plug Running & Retrieving Tools

• Catch tools – for retrieving frac plugs that didn’t drill out (emergency)

• Debris mills – for cleaning out fragments after plug drill‑out

• Impression blocks – for verifying plug position before setting

Applications – Where Our Fracturing Tools Are Used

Our downhole fracturing tools are deployed in every type of stimulation and well abandonment operation:

• Plug‑and‑perf multi‑stage fracturing – horizontal shale wells (Sichuan, Ordos, Permian‑type basins)

• Tight gas sandstone fracturing – vertical or slightly deviated wells, limited entry

• Coiled tubing fracturing – slim‑hole tools for 2‑3/8″ tubing

• Well abandonment and plug‑back – permanent cast iron bridge plugs

• Zone isolation for production testing – retrievable packers

• Refracturing existing wells – composite plugs with extended temperature rating

• Acid fracturing – corrosion‑resistant plugs and packers (FKM seals, stainless steel components)

• Geothermal well stimulation – high‑temperature plugs (up to 200°C available on request)

Why Choose SJ Petro for Fracturing Tools?

Because your downhole isolation is only as good as the tools you run – and we don’t cut corners on materials or testing.

Your Concern	SJ Petro’s Answer
"We’ve had composite plugs that didn’t drill out – took hours per plug.”	Our composite plugs use a glass‑filled matrix that drills consistently. We provide drill‑out parameters (WOB, RPM) to optimize time. Field average: 8–12 minutes per plug.
"Dissolvable plugs are great until they dissolve too early or not at all.”	We customize dissolution rate based on your well temperature and fluid chemistry. We provide lab dissolution curves before shipping – not just a generic claim.
"Setting tools sometimes fail to release – then we’re stuck.”	Our hydraulic setting tools have a positive release mechanism with a large bypass area. We’ve run thousands without a hang‑up. Field service engineers on call.
"We need API certification for tender requirements.”	Our packers and bridge plugs are designed and tested to API 11D1. Third‑party witnessed testing available.
"Lead times from major brands are 3‑4 months.”	Standard composite plugs: 2–3 weeks. High volume orders: 4–6 weeks. We stock common sizes.

More reasons downhole tool operators trust SJ Petro:

• Sinopec Group quality systems – ISO 9001, API Q1 certified manufacturing

• API 11D1 design – our packers and bridge plugs meet international downhole tool standards

• In‑house material science – we formulate our own composite materials and dissolvable alloys

• Large‑scale production – we’ve supplied over 100,000 frac plugs to a single shale gas operator

• Custom engineering – non‑standard casing sizes, high‑temperature (200°C), H₂S service (EE/NACE)

• Complete downhole solution – plugs, balls, setting tools, packers, drill‑out mills – one supplier

• Global shipping – we export to Russia, Middle East, Central Asia, Southeast Asia, and the Americas

Frequently Asked Questions (FAQ) – Fracturing Tools

Q1: What is the difference between a composite frac plug and a cast iron bridge plug?

A: Composite frac plug – Drillable body made from glass‑filled composite. Designed for temporary isolation during multi‑stage fracturing. Fast drill‑out (5–15 minutes per plug). Remaining fragments are small and non‑damaging. Best for: Plug‑and‑perf operations where you will drill out all plugs after fracturing.

Cast iron bridge plug – Body made from ductile cast iron. Provides permanent, metal‑to‑metal sealing. Slower to drill out (30–60 minutes per plug) but holds long‑term. Best for: Well abandonment, zone isolation (lower completion), plug‑back operations where the plug will remain in place for years.

Q2: How long does it take to drill out a composite frac plug?

A: With a coiled tubing unit and a standard PDC bit (properly dressed for composite), our customers average 8–12 minutes per plug. Factors that affect drill‑out time: bit condition, weight on bit, rotational speed, and fluid circulation. We provide recommended drill‑out parameters with each shipment.

Q3: How do I select the right ball seat size for my frac plug?

A: Ball seat size determines which ball will land and isolate the stage. In plug‑and‑perf operations, you typically run progressively smaller seats from toe to heel (e.g., 1.75″ seat in the toe, then 1.50″, 1.25″, etc.). The ball size for a given stage must be larger than the seat it lands on, but smaller than the seat in the plug above. We can help you design your ball seat progression based on your number of stages and tubing dimensions.

Q4: What is the temperature rating of your dissolvable plugs? Can I use them in deep, hot wells?

A: Our standard dissolvable alloy is rated to 120°C (250°F) . For higher temperatures (up to 150°C), we use a modified alloy – dissolution time becomes very fast (sometimes 1–2 days). For wells above 120°C, we recommend composite plugs + dissolvable balls, or we can engineer a custom dissolvable plug with controlled dissolution at your specific temperature. Contact us with your well temperature for a recommendation.

Q5: How do I know my well fluid will dissolve the dissolvable plug?

A: Dissolvable alloys require electrolytic fluid – typically produced brine (high chlorides) or certain fracturing fluids. Fresh water or hydrocarbon (oil/gas) does not cause dissolution. We will ask for a fluid sample or analysis from your well, then run a lab dissolution test and provide a curve (time vs. temperature). If your fluid won’t dissolve the plug, we’ll recommend a standard composite plug instead. We don’t sell dissolvable plugs where they won’t work.

Q6: What setting tool do I need for your frac plugs – mechanical or hydraulic?

A: Most plug‑and‑perf operations use hydraulic setting tools conveyed on wireline or e‑line. Pump pressure (typically 1,500–3,000 PSI across the tool) activates the setting mechanism. We also offer mechanical setting tools for use on jointed pipe or coiled tubing (without pump pressure). Choose based on your conveyance method. We stock both.

Q7: Are your fracturing tools compatible with other brands (Baker, Halliburton, Schlumberger, etc.)?

A: Our tools are designed with standard dimensions and industry‑standard connection threads. Our composite frac plugs will run and set with most major brands’ setting tools (with the correct adapter). However, for guaranteed compatibility, we recommend using our setting tools with our plugs. Mixing brands can work, but we’ve seen clearance issues and release failures. If you have an existing fleet of tools from another manufacturer, tell us the model numbers – we’ll advise.

Q8: What is the maximum differential pressure your frac plugs can withstand?

A: All our frac plugs (composite, cast iron, dissolvable) are rated to 10,000 PSI (69 MPa) differential pressure across the plug. For higher pressures (up to 15,000 PSI), we offer a heavy‑duty composite plug with reinforced slip segments and a thicker seal element – available on request. Confirm your expected treating pressure when ordering.

Q9: Do you provide field technical support for plug setting and drill‑out?

A: Yes. For large projects or first‑time customers, we can provide:

• On‑site technician during the first few plug runs

• Remote video support (WhatsApp/WeChat/Teams) for troubleshooting

• Written setting and drill‑out procedures

• Training for your wireline and coil tubing crews

We want your first job to go smoothly – we’ll make sure you have the support you need.

Q10: What are the lead times for standard composite frac plugs?

A: We maintain inventory of common sizes (5‑1/2″, 7″) in our factory. Lead time for stocked sizes: 2–3 weeks. For non‑stock sizes or high volumes (>500 pieces), lead time is 4–6 weeks. Dissolvable plugs and custom alloys take 6–8 weeks.

Q11: Do you sell frac plugs in small quantities (e.g., 10–20 pieces) for a single well?

A: Yes. We have no minimum order quantity. However, for orders under 50 pieces, the unit price is higher than bulk pricing. We can quote small volumes. Many independent operators buy 10–20 plugs per well.

Q12: Can I get a sample plug for fit‑up testing before placing a large order?

A: Yes. We can provide one or two sample plugs (non‑functional or functional) at a reduced cost (often free for large potential orders). You can run them through your casing to check clearance, set them in a test fixture, or drill them out to verify times. Contact our sales team.

Q13: What is the warranty on fracturing tools?

A: 12 months from shipment or 3 months from first use (whichever occurs first). The warranty covers manufacturing defects (cracks in composite body, faulty seal element, etc.). It does not cover damage from misuse, improper setting, or exceeding pressure/temperature ratings. Dissolvable products are warrantied for dissolution performance only if used under the fluid and temperature conditions we approved.

Q14: Do you manufacture tools for H₂S (sour gas) service?

A: Yes. For sour service, we offer:

• Composite plugs with NACE‑compatible elastomers (HNBR or FKM)

• Cast iron bridge plugs with corrosion‑resistant coating

• Dissolvable alloys with sulfide‑stress cracking resistance (tested per NACE TM0177)

Specify H₂S partial pressure and temperature when ordering. Additional lead time may apply.

Q15: Can you provide third‑party performance testing (e.g., witnessed setting and pressure test)?

A: Yes. We can arrange for third‑party inspection (SGS, BV, DNV, etc.) at our facility – cost is buyer’s expense. We can also provide an API 11D1 test report (internal) as standard documentation.

Q16: I need a custom tool for a non‑standard casing size. Can you engineer it?

A: Yes. We’ve built tools for casing sizes from 2‑7/8″ up to 13‑3/8″. Provide your casing ID, drift, weight, and grade. We’ll design a custom composite or cast iron plug with appropriate expansion range. Custom tools require engineering lead time (4–8 weeks) and have a minimum order quantity (typically 10–20 pieces).