Record-setting lateral completion achieved with Obsidian® Plugs

Overview

In the Utica Shale, Eclipse Resources chose to optimize well development cost through the use of longer laterals or “superlaterals”. In the Purple Hayes project, the lateral was a record 18,544 ft in length and 27,034 ft in total measured depth. One-hundred, twenty-four Obsidian plugs were set in a 5 1/2-in., 23-lb/ft P-110 casing with an average of 5.3 frac stages per day. In the first 10 runs a maximum pump-down rate of 18 bpm and a maximum line speed of 417 ft/min were achieved. All plugs were tagged on depth during the drillout process, taking an average of seven to 10 minutes per plug. 

Challenge

Setting and drilling out 100 + frac plugs in an extended-reach 18,544 ft lateral is no easy feat, so finding a reliable, field-proven completion solution was key. Eclipse Resources considered running a sleeve system for the extended lateral; however, Obsidian plugs proved to be a more economical option, and past experience gave the operator confidence in the success of this technology. 

Solution

Obsidian frac plugs are made from composite material without using any metal parts. They have a reputation for drilling out in a short time with the right size cuttings; which provides quicker drillout times by not bridging off the backside of the tubing or clogging the flowback screens. 

The Halliburton wireline adaptor kits used in setting plugs are engineered with an outside diameter that provides optimum dimensions to avoid presets. 

All of the plugs were tagged on depth during the drillout process, which used only two roller-cone bits with a 3 1/8-in. mud motor on a standalone unit. 

The first roller-cone bit drilled out 70 Obsidian frac plugs without a short trip, and the second roller-cone bit had only one short trip after 30 Obsidian plugs were drilled out. The 3 1/8-in. mud motor operated at 200 revolutions per minute with a pump rate through the tubing of 3-4.5 bpm, which resulted in 250-275 revolutions per minute at the bit.

Result

The well was completed in 23.5 days, placing a plug-and-perf hydraulic fracturing stage every 150 feet along the 3.5 mile-long lateral. Halliburton and Eclipse Resources set 124 frac plugs averaging 5.3 frac stages per day, and achieved a North America land record of 26,641 feet in plug setting depth. 

This achievement offers more evidence to support the reliable reputation of the Halliburton Obsidian frac plugs, even when tested in lateral lengths not reached before.