Hydro-Mechanical Set Bridge Plug | API 11D1 | 10,000 PSI | Cast Iron Drillable | Tubing Pressure Set

Our Hydro-Mechanical Set Bridge Plug is a high-performance downhole tool specifically engineered for reliable zonal isolation in oil and gas well operations. Combining hydraulic actuation with mechanical tension setting - a dual setting mechanism that initiates via tubing pressure and completes with mechanical tension - this tool delivers precise, secure sealing in both temporary and permanent wellbore isolation scenarios, ensuring operational safety and efficiency across diverse downhole conditions. The dual ratchet lock rings store setting force, preventing accidental release and maintaining a secure seal under dynamic downhole conditions including pressure fluctuations and highly deviated wellbores. Constructed from drillable cast iron with high-strength steel case-hardened slips and one-piece elastomer packing elements (available in Nitrile, HNBR, Aflas, or Viton) with metallic backup rings, the plug provides reliable pressure containment rated at 5,000 PSI (34 MPa) or 10,000 PSI (69 MPa), with standard temperature resistance up to 325°F (163°C) - customizable for higher temperature applications. The 360-degree case-hardened slips with angled backup design provide secure anchoring in all casing grades up to V-150, while the anti-preset and anti-swab design eliminates premature setting during running. The slim, compact profile allows for faster and safer run-in speed even in restricted wellbore spaces, and the integrated hydraulic-mechanical setting mechanism eliminates the need for complex wireline or e-line setting tools - simplifying operation and reducing equipment requirements. Unlike wireline-set bridge plugs that require specialized electric line or slickline equipment, the HM Bridge Plug is set by applying pressure through the tubing or drill pipe, making it ideal for wells where wireline access is limited, unavailable, or cost-prohibitive. The retrievable hydraulic setting tool is reusable multiple times, lowering overall operational costs. After use, the cast iron plug body can be easily drilled out with PDC bits, producing minimal debris. The plug can also be converted to a cement retainer with optional conversion kits, expanding its application range. Designed with field-proven technology and compatible with most casing grades, adaptable to HPHT environments, this plug is an ideal solution for well testing, stimulation, cementing, multi-zone fracturing, plug-and-abandonment operations, and high-pressure well emergency response - where it reduces operational time by over 60% compared to traditional well killing methods while avoiding reservoir contamination.

1. Hydro-Mechanical Dual Setting Mechanism with Dual Ratchet Lock Rings

Setting is initiated by hydraulic tubing pressure and completed with mechanical tension - ensuring stable and reliable setting even in highly deviated wells where pure hydraulic set plugs may be less reliable. The dual ratchet lock rings store and maintain setting force, preventing accidental release and sustaining a secure seal under dynamic downhole conditions including pressure reversals and vibration. This combined hydraulic-mechanical approach provides the reliability of mechanical locking with the convenience of hydraulic activation.

2. Superior Sealing Performance with One-Piece Packing Element

Equipped with a one-piece high-quality elastomeric packing element - available in Nitrile, HNBR, Aflas, or Viton to match downhole fluid and temperature conditions - and metallic backup rings, the plug effectively prevents fluid or gas leakage and avoids rubber extrusion in high-pressure environments. The one-piece packing element design enhances sealing integrity and durability compared to multi-element systems, while the metallic backup rings provide anti-extrusion support at elevated pressures and temperatures.

3. Drillable Cast Iron Construction with Reusable Setting Tool

Constructed from cast iron, the bridge plug can be easily drilled out with PDC bits after use, reducing operational time and debris generation compared to steel plugs. The retrievable hydraulic setting tool is separate from the plug body and is reusable for multiple setting operations, significantly lowering per-well equipment costs. The combination of a low-cost disposable cast iron plug and a reusable setting tool provides an economical solution for multi-well programs.

4. Anti-Preset and Anti-Swab Design with 360-Degree Case-Hardened Slips

Features 360-degree case-hardened slips and an angled backup design, eliminating premature setting during running-in and preventing swabbing effects that can cause unintended activation. The slips provide secure anchoring in all casing grades up to V-150, ensuring the plug stays in place during pressure testing and stimulation operations. The case-hardened slip teeth penetrate the casing wall for maximum holding force while remaining drillable with PDC bits.

5. Slim Profile and Easy Operation - No Wireline Required

The compact, slim-line design allows for faster and safer run-in speed, even in restricted wellbore spaces and through wellbore restrictions. The integrated setting mechanism eliminates the need for complex wireline, e-line, or slickline setting tools - the plug is set by applying pressure through standard tubing or drill pipe - simplifying operation, reducing equipment requirements, and making it suitable for wells where wireline access is limited or unavailable.

6. Versatile Compatibility and Convertible to Cement Retainer

Available in casing sizes from 4½" to 13-3/8" (custom sizes available), compatible with standard tubing and drill pipe for deployment. The plug can be converted to a cement retainer with optional conversion kits, expanding its application range to squeeze cementing and single-trip cementing operations. Customization options include custom pressure/temperature ratings, tailored seal material selection, and OEM branding.

The Hydro-Mechanical Set Bridge Plug operates in five phases - running-in, hydraulic initiation, mechanical setting and locking, isolation, and drill-out:

Phase 1: Running-In

The plug is connected to the retrievable hydraulic setting tool and run into the wellbore on tubing or drill pipe. The slim profile and anti-swab design allow smooth passage through wellbore restrictions, and the anti-preset mechanism prevents accidental activation during running. The plug can be run at optimized speeds through vertical, deviated, and horizontal sections.

Phase 2: Hydraulic Initiation

Once on depth, pressure is applied through the tubing/drill pipe. The hydraulic pressure initiates the setting sequence by activating the hydraulic cylinder in the setting tool, which begins to compress the plug assembly. This hydraulic initiation provides consistent, controlled force regardless of wellbore deviation.

Phase 3: Mechanical Setting and Locking

After hydraulic initiation, mechanical tension - applied by pulling the tubing/drill pipe upward - completes the setting process. The slips expand and anchor to the casing wall, while the packing element compresses radially to form a pressure-tight seal. The dual ratchet lock rings engage and store the setting force, mechanically locking the plug in the set position. The setting force is maintained by the ratchet mechanism even if hydraulic pressure is released.

Phase 4: Setting Tool Release and Isolation

After the plug is set and locked, the retrievable hydraulic setting tool is released - by right-hand rotation (primary method) or shear release - and retrieved to surface, leaving the plug in place as a permanent or temporary pressure barrier. The plug then provides reliable zonal isolation for the intended operation - well testing, stimulation, cementing, fracturing, abandonment, or emergency well control. The dual ratchet lock rings maintain sealing force throughout the isolation period.

Phase 5: Drill-Out (or Conversion)

When isolation is no longer required, the cast iron plug body is drilled out using PDC bits on coiled tubing or drill pipe, producing small, easily circulated debris. Alternatively, the plug can be converted to a cement retainer using optional conversion kits for squeeze cementing operations before drill-out.

We understand that every well operation has unique requirements, so we offer comprehensive OEM/ODM customization services:

• Custom casing sizes and dimensions (4½" to 13-3/8" standard, other sizes on request)

• Custom pressure and temperature ratings (standard 5K/10K PSI and 325°F, higher ratings available)

• Tailored seal material selection based on downhole fluid and temperature conditions (Nitrile, HNBR, Aflas, Viton)

• Customizable setting and release mechanisms

• Custom conversion kits (e.g., wireline to mechanical set conversion, cement retainer conversion)

• OEM logo printing and custom packaging

• Custom slip material and casing grade compatibility

Lead time for custom orders: 15–30 working days depending on customization complexity; sample evaluation units available before bulk orders.

Our Hydro-Mechanical Set Bridge Plug is manufactured under an ISO 9001:2015 certified quality management system and designed and manufactured in accordance with API 11D1 specifications for downhole packers and bridge plugs. We conduct rigorous testing for each product:

Raw Material Control

Cast iron and high-strength steel components are sourced from approved suppliers and accompanied by material test reports (MTR) verifying chemical composition, tensile strength, hardness, and microstructure. Elastomer packing elements are tested for hardness, tensile strength, compression set, and fluid compatibility.

In-Process and Finished Product Testing

• Hydrostatic Pressure Seal Test: Each assembled plug is pressure tested up to 120% of rated pressure with zero visible leakage as the pass criterion

• Setting and Release Function Test: Sample plugs from each production lot are set and released in test casing to verify hydraulic initiation, mechanical tension setting, ratchet locking, and setting tool release (right-hand rotation and shear)

• Drillability Test: Representative samples are drilled with PDC bits to verify drill-out time and cutting characteristics

• Temperature Resistance Test: Packing elements tested at rated temperature for compression set and sealing integrity

• Material Strength and Corrosion Resistance Tests: Verified per applicable standards

Warranty

We provide a 12-month warranty from the date of shipment against manufacturing defects in materials and workmanship, with 24-hour technical support for installation, operation, and troubleshooting.

1. Temporary and Permanent Zonal Isolation

Isolates lower well zones while testing, cementing, stimulating, producing, or injecting into upper sections, preventing fluid or gas cross-contamination between zones. Suitable for both short-term temporary isolation (well testing, stimulation) and long-term permanent isolation (well abandonment), with the dual ratchet lock mechanism maintaining sealing force for extended periods.

2. Well Plug and Abandonment (P&A)

Ideal for permanent well abandonment or temporary isolation during workover operations, ensuring long-term wellbore integrity. The cast iron construction provides a durable, cost-effective permanent barrier, and the 10,000 PSI rating meets regulatory requirements for well abandonment in most jurisdictions. The tubing-pressure setting method eliminates the need for wireline intervention during P&A operations.

3. High-Pressure Well Emergency Response

Suitable for emergency rescue and well control in wellhead leakage or kick scenarios, providing a rapid downhole pressure barrier. The hydraulic-mechanical setting through tubing reduces operational time by over 60% compared to traditional well killing methods, while avoiding reservoir contamination caused by heavy kill weight fluids. The 10,000 PSI rating handles high-pressure well control situations.

4. Multi-Zone Stimulation and Fracturing

Enables efficient multi-zone fracturing by isolating target zones between stages. The no-wireline setting method is particularly advantageous in offshore and remote locations where wireline equipment availability is limited, and the slim profile allows deployment through restricted wellbore geometries in deviated and horizontal wells.

5. Cementing and Squeeze Cementing Operations

Can be used in squeeze cementing and single-trip cementing operations, ensuring proper cement plug placement and preventing leakage. With optional conversion kits, the plug can be converted to a cement retainer for precise squeeze cementing applications - eliminating the need for a separate retainer tool and reducing trip count.

Q: What is the difference between hydro-mechanical set and pure hydraulic set bridge plugs?

A: The hydro-mechanical set bridge plug combines hydraulic actuation (to initiate setting via tubing pressure) and mechanical tension (to complete setting by pulling the tubing upward), secured by dual ratchet lock rings that mechanically store and maintain setting force. This dual mechanism provides more stable and reliable sealing in complex downhole conditions - especially highly deviated wells where pure hydraulic set plugs may experience incomplete setting or pressure loss. Pure hydraulic set plugs rely solely on hydraulic pressure for setting and do not have the mechanical locking backup.

Q: Can this bridge plug be retrieved after setting?

A: This is a drillable cast iron bridge plug designed for temporary or permanent isolation. It cannot be retrieved intact after setting - the retrievable component is the hydraulic setting tool, which is released (by right-hand rotation or shear) and retrieved to surface after the plug is set. The plug body remains in the well and can be easily drilled out with PDC bits when isolation is no longer required, leaving minimal debris. For applications requiring intact retrieval, we offer our Retrievable Bridge Plug - contact us for details.

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

A: The MOQ is 1 piece for standard models, with bulk order discounts available. Standard products ship within 7–15 working days after deposit; custom sizes, pressure ratings, or configurations require 15–30 working days. Sample evaluation units are available with 3–5 working day lead time, and sample costs can be deducted from bulk order payments. We ship from Shanghai or Ningbo port. Payment terms include T/T (30% deposit, 70% before shipment), L/C at sight, and Western Union.

Q: What setting equipment is required?

A: No specialized wireline, e-line, or slickline equipment is required. The plug is set by applying pressure through standard tubing or drill pipe, using our retrievable hydraulic setting tool. The setting tool is reusable for multiple operations and is available for purchase or rental. After setting, the tool is released by right-hand rotation (primary) or shear and retrieved with the tubing. We provide complete running and setting procedures with each order.

Q: What after-sales support and warranty do you provide?

A: We provide a 12-month quality warranty from the date of shipment against manufacturing defects in materials and workmanship. Our engineering team provides technical guidance for installation, setting procedure optimization, drill-out operation, and troubleshooting, with 24-hour online after-sales support. Material test reports, pressure test certificates, and operating instructions are included with every shipment.

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