Composite Bridge Plug | 10,000 PSI | -40°F to 400°F | Ball Drop / Flo-Back Config | 10–30 Min Drill-Out | Baker #5/#10/#20 Compatible

Our Composite Bridge Plug is a high-performance downhole isolation tool specifically engineered for oil and gas well drilling, completion, and stimulation operations where reliable temporary or permanent zonal isolation is required. Unlike conventional all-cast-iron bridge plugs, our composite design uses proprietary non-metallic composite materials - high-strength composite fibers reinforced with epoxy resin and ceramic components - with low metallic content, resulting in a lightweight yet structurally robust tool that offers excellent chemical resistance, high tensile strength, and low permeability for long-term sealing integrity in corrosive and high-stress downhole environments. The plug is equipped with millable cast iron slips that provide secure anchoring in most casing grades - including premium grades such as P110 and Q125 - and a one-piece packing element with metal backup rings that ensures bidirectional pressure sealing to prevent fluid leakage from either direction. The anti-rotation design features a positive lock-up mechanism and slip cone geometry that prevents the plug from spinning during mill-out, protecting casing integrity and ensuring safe, smooth, and predictable removal. When the operation is complete, the composite construction allows the plug to be quickly and easily milled and circulated back to surface with consistent drill-out times ranging from 10 to 30 minutes depending on plug size - significantly faster than all-cast-iron alternatives and minimizing operational downtime and milling costs. A key advantage of this composite bridge plug is its flexible configuration system. The base model adopts a ball-drop configuration, and it can be combined with on-the-fly inserts - including a standard bridge plug insert, a flo-back insert for pressure equalization, and a flo-back insert with bio-ball for dissolvable ball applications - providing optimum on-site versatility without requiring multiple plug models. Custom outer diameter (OD) and inner diameter (ID) options are available upon request to meet specific well requirements. The plug can be set on slickline/e-line, coiled tubing, or production tubing using conventional setting tools such as Baker #5, Baker 10/20, and Magnum "A-1", with a universal setting sleeve and adapter for easy operation - no additional crossover tools required. Rated up to 10,000 PSI with a temperature range from -40°F to 400°F (custom high-temperature elastomer options available), this tool is widely applied in vertical, horizontal, and deviated wells across global oil and gas fields - including multi-stage fracturing, zone testing, well abandonment, squeeze cementing, workover, bottom-water sealing, and gas well operations with top-venting pressure equalization during drill-out - delivering cost-saving and efficiency-boosting solutions for well operators worldwide, with proven field performance in the Middle East, North America, and Asia-Pacific.

1. Efficient 10–30 Minute Drillability

Made of high-grade non-metallic composite materials with low metallic content, the plug can be quickly and easily milled and circulated back to the surface with consistent drill-out times ranging from 10–30 minutes depending on plug size - significantly faster than conventional all-cast-iron bridge plugs. The composite body produces fine, easily circulated cuttings that do not damage the casing or cement sheath, minimizing operational downtime and reducing milling costs and bit wear. The anti-rotation design ensures predictable, spin-free mill-out for consistent removal time across all plug sizes. 2. High Pressure & Temperature Rating (-40°F to 400°F)

Rated up to 10,000 PSI differential pressure with a standard operating temperature range from -40°F to 400°F (-40°C to 204°C), the plug maintains stable sealing and structural performance in harsh downhole environments including corrosive fluids and high-stress conditions. Custom high-temperature elastomer options are available for applications exceeding 400°F - contact our engineering team for specific temperature ratings based on your wellbore fluid chemistry and elastomer selection. The one-piece packing element with metal backup rings maintains seal integrity across the full temperature and pressure range.

3. Versatile Setting Methods with Universal Setting Sleeve

Can be set on slickline/e-line, coiled tubing, or production tubing using conventional setting tools - including Baker #5 for smaller sizes (2-7/8", 3½"), and Baker 10/20 for larger sizes (4½", 5½", 7"), as well as Magnum "A-1" setting tools. The universal setting sleeve and adapter design enables easy operation without additional crossover tools, reducing equipment needs and setup time at the wellsite. This multi-conveyance flexibility allows the same plug model to be deployed across different rig types and operational preferences.

4. Reliable Sealing & Anchoring in Premium Casing

Equipped with millable cast iron slips and a one-piece packing element with metal backup rings, ensuring secure anchoring in most casing grades - including premium grades like P110 and Q125 - and bidirectional pressure sealing to prevent fluid leakage from either above or below the plug. The metal backup rings prevent packing element extrusion under high differential pressure, and the cast iron slips provide reliable casing engagement without excessive casing damage during mill-out.

5. Anti-Rotation Positive Lock-Up Design

Features a positive lock-up mechanism and slip cone design to prevent the plug from spinning during milling - protecting casing integrity and ensuring safe, smooth, and predictable removal. The anti-rotation feature eliminates the risk of the plug backing off or rotating during drill-out, which can cause uneven cutting, extended mill-out time, and potential casing damage. This design ensures consistent drill-out performance across all well conditions.

6. Flexible Ball-Drop & Flo-Back Configurations

The base model adopts a ball-drop configuration for standard zonal isolation, and can be combined with on-the-fly inserts for optimum on-site versatility:

• Standard bridge plug insert - for conventional temporary or permanent isolation

• Flo-back insert - provides pressure equalization during drill-out for gas wells and pressure-sensitive applications

• Flo-back insert with bio-ball - uses a dissolvable ball for applications where ball retrieval is not feasible Custom outer diameter (OD) and inner diameter (ID) options are available upon request to meet specific well requirements, eliminating the need to stock multiple plug models for different operational scenarios.

7. Cost-Effective, Lightweight & Chemically Resistant

The lightweight composite design reduces transportation and handling costs compared to heavy all-metallic plugs, and the non-metallic composite materials offer superior chemical resistance, tensile strength, and low permeability - extending service life and reducing maintenance needs in corrosive downhole environments (CO2, H2S, brine). The low metallic content means less metal debris during mill-out, reducing circulating time and the risk of debris-related issues. Combined with fast drill-out and versatile setting, this plug delivers lower total operational cost than traditional metallic bridge plugs.

The Composite Bridge Plug operates through a reliable setting, isolation, and mill-out process:

Setting Process

1. The plug is connected to the appropriate setting tool - Baker #5, Baker 10/20, or Magnum "A-1" - based on plug size, and run into the wellbore via slickline/e-line, coiled tubing, or production tubing to the target setting depth. The universal setting sleeve and adapter eliminate the need for crossover tools.

2. The setting tool is activated - either by wireline firing mechanism, hydraulic pressure through coiled tubing or production tubing, or mechanical tension - generating the setting force.

3. The setting force acts on the lower sub through the cone, exerting compressive force on the packing element. Within the tension range, the cast iron slips rupture the slip retainer and embed into the inner wall of the casing, while the one-piece packing element expands to form a tight, pressure-tight seal with metal backup rings preventing extrusion.

4. When the tension continues to rise to a predetermined value, the shear pins break, separating the setting tool from the bridge plug. The positive lock-up mechanism engages, maintaining the setting force and preventing the plug from rotating or releasing.

5. The setting tool is retrieved to surface, leaving the composite bridge plug set and anchored in the casing. For ball-drop configuration: after the plug is set, a frac ball is dropped from surface and pumped down to seat on the plug's ball seat, allowing pressure to be applied above the plug for fracturing or testing operations.

For flo-back configuration: the flo-back insert provides a pressure equalization path during drill-out, preventing trapped pressure in gas wells.

Isolation Phase

Once set, the cast iron slips and compressed packing element create a reliable bidirectional pressure barrier containing differential pressure up to 10,000 PSI from either direction. Fracturing, zone testing, squeeze cementing, or other operations are performed above the plug. The anti-rotation lock-up maintains seal integrity during pressure cycling and dynamic operations.

Mill-Out Phase

Once the operation is completed, the composite plug can be quickly milled out with a PDC bit on coiled tubing or drill pipe according to subsequent production needs. The anti-rotation design prevents the plug from spinning during milling, ensuring smooth, predictable cutting. The non-metallic composite and cast iron materials produce fine, easily circulated cuttings. Drill-out time is typically 10–30 minutes depending on plug size. After mill-out, the well is ready for production or subsequent operations.

We offer comprehensive customization to match specific well conditions:

• Custom casing sizes beyond the standard 2-7/8" to 7" range

• Custom OD and ID dimensions for special casing or wellbore restrictions

• Custom high-temperature elastomer packing elements (HNBR, Viton, Aflas) for temperatures exceeding 400°F

• Configuration selection: ball-drop (standard), flo-back, or flo-back with bio-ball

• Custom slip material for special casing grades (including P110, Q125, and premium grades)

• Setting tool compatibility options (Baker #5/#10/#20, Magnum A-1, or other brands)

• Custom color coding for size and configuration identification

• OEM/ODM branding and custom packaging

• Top-venting configuration for gas well pressure equalization during drill-out Lead time for custom orders: 15–25 working days depending on complexity; sample evaluation units available before bulk orders.

- Complies with API Spec 11D1 standards for subsurface downhole isolation tools, ensuring high quality and compatibility with industry requirements. (Note: API 7-1 applies to rotary drillstring components and is not the applicable standard for bridge plugs - please verify certification documentation.)

- Manufactured under an ISO 9001:2015 certified quality management system with strict quality control processes, including raw material testing, hydrostatic pressure testing, temperature resistance testing, and dimensional inspection.

- Each plug undergoes 100% hydrostatic pressure seal testing at rated pressure before shipment, with material test reports (MTR) and pressure test certificates provided with every order.

- 12-month warranty period from date of shipment, providing after-sales support and technical assistance for any product issues, with 24-hour response to inquiries.

- Third-party inspection (BV, SGS, DNV) and CE certification available on request. All products traceable by material batch number and serial number.

1. Temporary Isolation for Multi-Stage Completion

Provides reliable temporary zonal isolation for multi-stage vertical or horizontal well completion operations, enabling stage-by-stage fracturing and stimulation without fluid cross-flow between zones. The ball-drop configuration supports standard plug-and-perf completions, and the fast 10–30 minute drill-out reduces transition time between stages and overall completion duration. The versatile setting methods allow deployment on rigs with or without wireline capability.

2. Zone Fracturing, Stimulation, and Testing

Enables efficient zone fracturing, stimulation, and well testing to improve well productivity, with bidirectional pressure sealing up to 10,000 PSI that withstands high-rate fracturing pressure cycles. The anti-rotation design ensures the plug remains stable during high-pressure stimulation, and the metal backup rings prevent packing element extrusion under sustained pressure. Compatible with P110 and Q125 premium casing grades common in high-pressure fracturing applications.

3. Temporary or Permanent Well Abandonment

Suitable for both temporary isolation during well interventions and permanent well abandonment (P&A), providing long-term, high-integrity isolation that meets regulatory requirements. For temporary applications, the plug can be milled out if future re-entry is required; for permanent abandonment, the composite and cast iron construction provides durable long-term isolation. The lightweight design reduces logistics costs for P&A campaigns across multiple wells.

4. Squeeze Cementing and Workover Operations

Works as a reliable downhole barrier during squeeze cementing and workover operations - isolating lower zones while cement is squeezed above the plug, or providing a pressure barrier during wellbore repair and maintenance. The flo-back configuration option provides pressure equalization during retrieval/mill-out for workover operations where pressure management is critical.

5. Bottom-Water Sealing and Zone Selection for Fracturing

Used for bottom-water sealing applications in wells with water encroachment, and for zone selection in casing-well fracturing operations where specific intervals must be isolated to target hydrocarbon-bearing zones. The reliable bidirectional seal prevents water influx from below during fracturing and production, and the composite materials resist degradation in water-producing environments.

6. Gas Well Operations with Top-Venting Configuration

Suitable for gas well operations where pressure equalization during drill-out is critical - the flo-back or top-venting configuration allows pressure to equalize above and below the plug during mill-out, preventing the plug from being lifted by trapped gas pressure and ensuring safe, controlled removal. This is particularly valuable in high-pressure gas wells where conventional plug mill-out can be hazardous due to trapped pressure.

Q: What materials are used in the composite bridge plug?

A: The plug body is made of high-strength non-metallic composite fibers reinforced with epoxy resin and ceramic components, with low metallic content. The slips are millable cast iron for secure casing anchoring, and the packing element is a one-piece elastomer with metal backup rings. This combination offers excellent chemical resistance, high tensile strength, and low permeability - while remaining fully PDC-millable with fine cuttings.

Q: What is the correct temperature rating? I see -40°F and -250°F referenced.

A: The standard operating temperature range is -40°F to 400°F (-40°C to 204°C). The -250°F value in the previous specification table was an error and has been corrected. Custom high-temperature elastomer options (HNBR, Viton, Aflas) are available for applications exceeding 400°F - contact our engineering team with your wellbore temperature and fluid chemistry for a specific elastomer recommendation.

Q: What is the difference between ball-drop, flo-back, and flo-back with bio-ball configurations?

A: • Ball-drop (standard): A frac ball is dropped from surface to seat on the plug's ball seat, allowing pressure application for fracturing/testing. The ball remains in place and is drilled out with the plug.

• Flo-back: Includes an insert that provides a pressure equalization flow path during drill-out, preventing trapped pressure - ideal for gas wells and pressure-sensitive applications.

• Flo-back with bio-ball: Uses a dissolvable (bio) ball instead of a standard ball, eliminating the need to drill out the ball and reducing debris - suitable for applications where ball retrieval or drill-out is challenging. All three configurations use the same base plug body - only the insert differs, allowing on-site configuration flexibility.

Q: How long does it take to mill out the plug and what equipment is needed?

A: Drill-out times are consistent and efficient, ranging from 10–30 minutes depending on the plug size (smaller plugs drill faster) and well conditions. A standard PDC bit on coiled tubing or drill pipe is used. The anti-rotation design prevents the plug from spinning during mill-out, ensuring smooth cutting. The composite and cast iron materials produce fine, easily circulated cuttings.

Q: What setting tools are compatible and does it require crossover tools?

A: The plug is compatible with Baker #5 (for 2-7/8" and 3½" sizes), Baker 10/20 (for 4½", 5½", and 7" sizes), and Magnum "A-1" setting tools. It can be run on slickline/e-line, coiled tubing, or production tubing. The universal setting sleeve and adapter design means no additional crossover tools are required - the plug connects directly to the standard setting tool.

Q: How does this compare to a cast iron bridge plug?

A: The main differences are: (1) Weight - composite plugs are significantly lighter, reducing transportation and handling costs; (2) Drill-out time - composite plugs drill out in 10–30 minutes vs. 30–60+ minutes for cast iron, with finer cuttings; (3) Chemical resistance - composite materials resist CO2, H2S, and brine better than cast iron; (4) Cost - composite plugs are generally higher unit cost but lower total operational cost due to faster drill-out and less debris; (5) Pressure/temperature - both reach 10,000 PSI and similar temperatures, but cast iron may be preferred for extreme permanent abandonment where maximum long-term durability is required.

Q: What is the MOQ, delivery time, and payment method?

A: The MOQ is 1 piece for standard models. Standard products ship within 7–15 working days after deposit; custom sizes or configurations require 15–25 working days. We ship from Shanghai or Ningbo port. Payment terms include T/T (30% deposit, 70% before shipment), L/C at sight, and Western Union. Sample evaluation units available for testing before bulk orders.

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