Optimizations in Hydraulic Fracturing Operations, the Impact of Using Dissolvable Frac Plugs in Saudi Arabia Fracturing Operations

Abstract Since 2017, dissolvable frac plugs have been deployed in Saudi Arabia for both unconventional and conventional development. Over 6,000 dissolvable plugs have been used, with 10% featuring acid-resistant coatings for acid fracturing. These plugs are categorized into two major types: Type 1, with a dual slip design capable of holding pressure from both sides, and another is Type 2, with a single slip design that enhances dissolution performance. This study also explores the applications of these plugs in acid and proppant fracturing operations. This study analyzes the performance of dissolvable frac plugs in various well conditions across Saudi Arabia. The Type 1 plugs, with their dual slip design, were tested for their ability to maintain pressure integrity from both directions, while the Type 2 plugs were evaluated for their dissolution efficiency and drift rate. Data was collected from field deployments, focusing on parameters such as pressure holding capacity, dissolution time, and operational efficiency. Additionally, the impact of acid-resistant coatings on plug performance during acid fracturing was assessed. Proppant applications were also examined to determine the plugs’ effectiveness in maintaining fracture conductivity and preventing proppant flowback. The Type 1 plugs demonstrated excellent pressure rating up to 13,000 psi 30% increase, effectively holding pressure from both sides, which is crucial for maintaining well integrity during fracturing operations. The Type 2 plugs exhibited superior dissolution performance in 95 hours, ensuring no residual material obstructed the wellbore. Additionally, the acid-resistant coated plugs performed reliably in acid fracturing environments, preventing premature degradation. The collected data indicates that the use of dissolvable plugs significantly reduces the time and cost (milling time 3 days and cost reduction of 15%) associated with post-fracturing well interventions. By eliminating the need for coiled tubing milling or drifting, operators can transition from fracturing to production more swiftly, enhancing overall operational efficiency. This improvement not only optimizes the workflow but also contributes to cost savings and increased productivity, making dissolvable plugs a valuable innovation in hydraulic fracturing operations. The ability to move seamlessly from fracturing to production without additional interventions underscores the practical benefits of these advanced plugs, highlighting their role in modernizing and streamlining hydraulic fracturing processes. The innovative use of dissolvable frac plugs in high-temperature, high-pressure (HTHP) wells present a significant advancement in hydraulic fracturing technology. The ability to flow back and produce directly without the need for coiled tubing interventions not only saves time and costs but also reduces operational risks. This approach accelerates the production timeline and offers a viable solution for wells with deformed casing, where traditional coiled tubing re-entry might be challenging.