What Is a Hybrid Frac Plug?

You’ve used composite and dissolvable plugs, but hybrid frac plugs are a relatively new entrant in the oilfield tools industry. They combine both magnesium and composite materials to get all the best properties of each type of plug. Let’s dig further into what this type of frac plug is and what it means for your completion.

What is a hybrid plug made of?

Hybrid frac plugs typically use the same components as composite and dissolvable plugs. The composite pieces could include epoxy, thermoplastics, or other metal-free materials that will create a good seal and complete the zonal isolation. The dissolvable components are meant to degrade after a certain amount of time downhole, so they’re made out of a degradable material like magnesium.

How does a hybrid plug work?

Hybrid plugs work the same as any other type of frac plug, but they have different properties and benefits. They aim to combine the efficiency of dissolvable plugs with the dependability of composite plugs. Hybrid frac plugs are designed to partially degrade while still providing zonal isolation. So the parts you don’t need will fall apart, while the essential parts stay put.

What are the different types of hybrid plugs?

There are two main types of hybrid frac plugs: with and without a center mandrel. Hybrid plugs with a center mandrel have the necessary structure to support all of the plug’s exterior components, like the element, slips, and cones. The mandrel is essential for creating a rigid structure under load-bearing components to ensure zonal isolation, especially for ball-drop plugs.

Hybrid plugs without a center mandrel, on the other hand, are missing their skeleton and don’t have the same structural integrity. Getting a good seal is also more difficult. Having less material is supposed to make the plug drill out faster, but faster isn’t better when you don’t have a solid seal. In our opinion, there's increased integrity risk to a mandrel-less plug, with most of the benefit accruing to the supplier through lower material and manufacturing costs.

Do you need a hybrid frac plug?

Hybrid frac plugs attempt to give you the benefits of both composite and dissolvable plugs. You may get enhanced zonal isolation that comes with composites, with the hope of faster drill-outs and limited debris that you expect from a dissolvable plug.

That said, hybrid frac plugs are a newer type of product and can be more expensive to get your hands on. It’s likely easier and more cost-effective to get a reliable composite or proven dissolvable plug, depending on whether your completion needs reliable isolation or reduced drill out risk. Or, if you want to take a hybrid approach without a hybrid plug, you can use both composite and dissolvable plugs in different stages, depending on the downhole conditions throughout the length of the well.

Interested in learning more about the PurpleSeal™ composite frac plug and PurpleReign™ dissolvable plugs? Contact Repeat Precision today and let’s talk completions.