Success stories

Efficient Composite Frac Plug Removal with Full-Metal-Power

"Full-Metal-Power’s high-torque motor was a game-changer. It handled extreme temperatures and corrosive conditions with ease, milling each plug in minutes and getting us back to full production faster than we thought possible. This technology minimized our downtime and exceeded our expectations in every way."

Rigless intervention - Full-Metal-Power

Introduction to the Project

A client in Saudi Arabia needed a reliable solution to remove composite frac plugs in extreme downhole conditions, including temperatures up to 300°F and exposure to H2S/CO2. The goal was to restore production swiftly, without the delays and added costs typical of challenging well interventions. Full-Metal-Power’s high-torque motor was selected for its durability and power to handle these demanding conditions.

Rigless intervention - Full-Metal-Power

The Full-Metal-Power Solution

The operation deployed Full-Metal-Power’s high-torque motor, engineered to withstand high temperatures and corrosive environments. Operating as a rigless intervention, the motor utilized a co-mingled fluid mixture of water, nitrogen, and gel to support quick and effective plug removal while minimizing operational risk. By using a co-mingled fluid, the setup optimized milling speed and cooling, preventing heat-related setbacks that could impede performance.

The Result

Full-Metal-Power’s motor exceeded expectations, delivering fast and efficient results:

  • Milling Time: Each plug was removed in under 15 minutes, showcasing the motor’s high efficiency and power.
  • Circulation Time: Total circulation took 25 hours, allowing for thorough plug removal and consistent flow maintenance.
  • Outcome: Composite frac plugs were cleared rapidly, leading to an immediate restoration of production, reduced downtime, and minimized costs. The motor’s resilience in harsh conditions underscored its value for high-stakes, high-temperature interventions.

Conclusion

Full-Metal-Power’s high-torque motor delivered impressive durability and speed, making it an ideal choice for efficient frac plug removal in extreme downhole conditions. This successful intervention demonstrates Full-Metal-Power’s commitment to providing solutions that optimize production, even in the most demanding environments.

Ready to tackle challenging well conditions and boost production? Connect with Full-Metal-Power today.

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Proven performance in 37 countries

Proven in 37 countries, Full-Metal-Power’s metal-to-metal tech doesn’t just perform—it dominates. From geothermal to oil and gas, we eliminate elastomer failures and push efficiency to new heights, making sure your operations run harder, faster, and smarter, no matter the challenge.