Case Study: Vertechs’ Dissolvable Plug Solves Complex Fracturing Challenges
Introduction
In the ever-evolving landscape of oil and gas exploration, efficiency, reliability, and cost-effectiveness are the pillars of operational success. As drilling environments become more complex and reservoirs harder to access, traditional tools and methods often fall short. One of the major hurdles faced by operators today is achieving efficient zonal isolation during multistage hydraulic fracturing—especially in unconventional wells with high temperatures, variable pressures, or extended lateral lengths.
This case study explores how Vertechs’ advanced Dissolvable Plug technology successfully addressed a set of complex fracturing challenges for a major operator. By combining innovative materials, precise engineering, fluid rheology and field-proven reliability, Vertechs delivered a game-changing solution that not only simplified operations but also reduced costs and downtime significantly.
Background: The Challenge
The operator in this case study was developing a deep horizontal shale well with over 50 fracturing stages. The conditions were far from ideal—high bottomhole temperatures (BHT) exceeding 150°C, variable salinity levels, and extended lateral sections made it difficult for conventional composite plugs to perform consistently.
In previous wells, the operator had relied on composite bridge plugs, which required coiled tubing (CT) intervention for milling after fracturing. This process was time-consuming, costly, and risky due to the long lateral length and potential for debris interference. In some wells, residual plug material caused flow restrictions, delaying production and increasing cleanout time.
The operator sought an alternative solution that could:
Eliminate the need for post-fracturing milling.
Ensure complete dissolution under challenging downhole conditions.
Maintain mechanical strength and sealing integrity during high-pressure fracturing.
Reduce overall well completion time and costs.
Vertechs’ Solution: The Dissolvable Plug Advantage
After evaluating multiple technologies, the operator partnered with Vertechs, a global leader in wellbore completion and downhole innovation. Vertechs recommended its next-generation Dissolvable Plug, engineered specifically for high-temperature and high-salinity environments.
Unlike traditional composite plugs that rely on physical retrieval or milling, Vertechs’ Dissolvable Plug is made from proprietary metallic and polymeric materials that gradually dissolve in wellbore fluids after performing their isolation function. The plug provides robust sealing performance during fracturing and self-eliminates post-job, allowing for uninterrupted flowback and production.
Key features of Vertechs’ Dissolvable Plug include:
Temperature tolerance up to 180°C.
Customizable dissolution rates based on fluid composition and salinity.
High-pressure resistance, tested to withstand over 10,000 psi.
Simple deployment using standard wireline or plug-setting tools.
Implementation and Field Execution
The field test was conducted in a shale formation in Western China, characterized by high reservoir pressure and temperature gradients. well control The operator used Vertechs’ Dissolvable Plug to isolate each stage during the fracturing operation.
Step 1: Deployment
The plugs were deployed using conventional wireline equipment. Installation was smooth, with zero deviations in setting depth across all stages. Each plug was pressure-tested before the start of fracturing to ensure reliable sealing integrity.
Step 2: Fracturing Operation
Over 50 stages were fractured sequentially. Each Vertechs Dissolvable Plug successfully held differential pressure above 9,000 psi, demonstrating exceptional durability throughout the operation. Despite the harsh conditions, no pressure anomalies or leakages were recorded during any stage.
Step 3: Dissolution Phase
After completion of all stages, the well was shut in for 36 hours to allow natural fluid exposure and temperature-driven dissolution. Post-shut-in, the operator initiated flowback without any coiled tubing intervention. Within 72 hours, all plugs had fully dissolved, and full wellbore access was achieved.
Results and Performance Metrics
The results of the case study clearly demonstrated the superior performance of Vertechs’ Dissolvable Plug technology.
Operational highlights:
Zero milling operations were required.
No debris-related issues during flowback.
30% reduction in total completion time.
Significant improvement in initial production rates due to immediate well access.
Technical Insights: Why It Worked
The success of Vertechs’ Dissolvable Plug lies in its material science and design precision. The plug’s multi-phase alloy composition enables predictable dissolution behavior even under fluctuating downhole conditions.
Key technical differentiators include:
Adaptive Material Chemistry – Vertechs uses proprietary blends of metallic compounds that dissolve at controlled rates depending on fluid salinity and temperature.
Enhanced Sealing Mechanism – A unique elastomer design ensures leak-free performance during fracturing while maintaining structural integrity until dissolution begins.
High-Temperature Stability – The plug’s material resists premature degradation, ensuring operational reliability in extreme thermal environments.
Minimal Residual Byproduct – Unlike composite plugs that leave behind carbon fiber debris, Vertechs’ plug dissolves completely, leaving no obstruction for production flow.
Environmental and Economic Impact
In addition to operational efficiency, Vertechs’ Dissolvable Plug also contributed to sustainability and safety improvements. By removing the need for milling operations, the operator:
Reduced diesel consumption and emissions from coiled tubing units.
Minimized wellsite personnel exposure to potential hazards.
Lowered waste material generation, aligning with the company’s ESG objectives.
From a cost perspective, the operator reported a 25% overall savings in completion expenses. The shorter well turnaround also improved cash flow and allowed faster capital redeployment for future wells.
Client Feedback
The operator praised the Vertechs team for its technical expertise, responsiveness, and reliability throughout the project. In their words:
“The dissolvable plug solution exceeded expectations. Not only did it eliminate the need for costly cleanouts, but it also simplified our entire completion workflow. Vertechs’ technology proved to be both robust and predictable—critical for our high-temperature environment.”
Conclusion: Setting a New Benchmark in Downhole Efficiency
This case study highlights how Vertechs’ Dissolvable Plug technology can transform the way operators approach complex fracturing operations. Through advanced material science, precise engineering, and field-proven performance, Vertechs offers a reliable, intervention-free solution that enhances operational safety, reduces costs, and accelerates production timelines.
As unconventional drilling continues to evolve, the demand for smarter, more sustainable completion tools will only grow. Vertechs remains at the forefront of this transformation, helping operators achieve maximum efficiency and value from every well.
About Vertechs
Vertechs is a global technology company dedicated to delivering innovative downhole solutions for the oil and gas industry. From dissolvable tools and intelligent wellbore monitoring systems to pressure control and completion optimization, Vertechs continues to redefine performance standards across the energy sector.
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