Baker Hughes, a leading energy technology company, has successfully deployed its Versa-Drive™ plug milling service in two unique unconventional wells, each in one run, saving $150k USD for the operator. The Versa-Drive plug milling service is a coiled tubing-conveyed solution that uses advanced cutting structures and optimized mill designs to reliably remove frac plugs from long horizontal wellbores.
The challenge
The operator was developing two unconventional wells in the Permian Basin, one with a 10,000-ft (3,048-m) lateral and 50 composite frac plugs, and the other with a 7,500-ft (2,286-m) lateral and 40 composite frac plugs. The operator wanted to mill out all the plugs in each well in a single run, without any short trips or motor stalls, to reduce rig time and costs.
However, milling out frac plugs in extended lateral wells can be challenging, as conventional milling services may not have the technology or expertise to reach total depth (TD) reliably. Low permeability, high friction, and complex well geometries can hinder the performance and efficiency of conventional milling services, resulting in multiple runs, wasted time, and increased costs.
The solution
The operator chose Baker Hughes to perform the plug milling operations, based on the company’s proven track record and experience in unconventional wells. Baker Hughes deployed its Versa-Drive plug milling service, which leverages an arsenal of extended-reach technologies, advanced cutting structures, and optimized mill designs to reach TD in long horizontal wells.
The Versa-Drive plug milling service incorporates several tools that optimize the milling operation, such as:
- The Vanguard™ plug bit, the only bit in the industry specifically designed for extended-reach plug milling applications. The bit combines self-sharpening teeth, increased tooth count, and proprietary bearing technology to deliver efficient, reliable single-trip mill outs.
- The CIRCA Real-Time (RT) coiled tubing modeling software, which enhances safety and efficiency when deploying the Versa-Drive plug milling service on coiled tubing. The software seamlessly connects pre-job analysis with real-world variables to update simulations and ensure greater certainty of success.
- The operational support through stringent quality control, reliable execution, and powerful analytics software, which helps ensure an optimized milling run every single time.
The results
The Versa-Drive plug milling service delivered outstanding results in both wells, milling out all the plugs in each well in a single run, without any short trips or motor stalls. The service achieved an average mill out time of 8 minutes per plug, and a total rig time savings of 24 hours, compared to conventional milling services. The operator was able to save $150k USD in rig time and operational costs, and improve the connectivity with the reservoir by removing all the plugs through to the toe.
The table below summarizes the key performance indicators of the Versa-Drive plug milling service in the two unconventional wells:
| Well | Lateral length (ft) | Number of plugs | Mill out time per plug (min) | Total rig time savings (h) | Cost savings (USD) |
|---|---|---|---|---|---|
| 1 | 10,000 | 50 | 8 | 12 | 75,000 |
| 2 | 7,500 | 40 | 8 | 12 | 75,000 |
The Versa-Drive plug milling service is a proven solution for milling out frac plugs in extended lateral, unconventional wells, delivering unsurpassed milling efficiency, reliability, and cost savings. To learn more about the Versa-Drive plug milling service and how it can streamline your milling operations, contact Baker Hughes today.