Series Composite Bridge Plug | 10,000 PSI | 300°F | Standard / Ball Drop / Cage-Type | LUG Anti-Rotation | 10–20 Min Drill-Out | Baker 10/20

The Series Composite Bridge Plug is a critical downhole tool specifically developed to isolate specific sections of wellbores, enabling targeted operations such as high-pressure stimulation, frac treatments, and cementing processes. Unlike traditional all-metallic bridge plugs, our composite design offers significant advantages in drillability, weight reduction, and casing protection, while maintaining exceptional strength and sealing reliability under extreme downhole conditions. The plug body is fully constructed from high-strength, environmentally friendly composite materials, with cast iron used only in the slip assembly - this design maximizes the benefits of composite construction (lightweight, fast drill-out, minimal debris, chemical resistance) while retaining the proven anchoring reliability of cast iron slips that bite securely into the casing wall. A key differentiator of this series is its three configurable versions, allowing operators to select the optimal configuration for each well condition without changing tool families: the Standard Bridge Plug features a replaceable plug assembly for balanced pressure isolation supporting both positive and negative differential pressure; the Ball Drop Bridge Plug is the basic configuration that achieves positive differential pressure sealing by dropping a ball from surface after the plug is anchored; and the Cage-Type Bridge Plug features a replaceable cage assembly for positive differential pressure sealing after anchoring, specifically designed for complex well conditions where standard configurations may be less reliable. All three configurations share the same composite body, slip system, and setting interface, reducing training and inventory requirements. The unique LUG anti-rotation design prevents the plug from rotating with the mill shoe during drill-out, ensuring smooth, predictable milling and protecting casing integrity - a common pain point with composite plugs that lack anti-rotation features. The slip cone design further enhances anchoring stability and prevents rotation during mill-out. The cast iron slips bite into the casing wall with minimal depth, providing secure anchoring in P110 and other common casing grades without excessive casing damage. High-performance sealing elements ensure leak-proof bidirectional sealing under rated pressure. With multiple configurations and versatile setting methods, the Series Composite Bridge Plug adapts seamlessly to diverse well conditions and operational requirements. It can be set via wireline using BAKER 10 or BAKER 20 wireline setting tools, or via tubing/coiled tubing hydraulic setting using surface pump pressure. The universal setting sleeve and shear sub allow for quick plug replacement without disassembling the setting tool, and the reusable setting accessories further optimize operational expenses. Rated to 10,000 PSI with temperature resistance up to 300°F (149°C), and compatible with 4½" and 5½" casings (custom sizes available), this series provides a temporary yet robust barrier that can be quickly and efficiently milled out in 10–20 minutes after use, minimizing operational downtime and reducing overall project costs. It is an ideal choice for multi-stage fracturing, well testing, temporary well abandonment, cementing, and open-hole/cased-hole operations in shale gas, oil, and geothermal projects worldwide.

1. Advanced All-Composite Body with LUG Anti-Rotation

The plug body is fully made of high-strength, environmentally friendly composite materials - with cast iron used only in the slip assembly - ensuring excellent pressure and temperature resistance while enabling fast drill-out (10–20 minutes maximum, as low as 10 minutes depending on size) without damaging the casing. The unique LUG anti-rotation design prevents the plug from rotating with the mill shoe during drilling, ensuring smooth, predictable cutting, reducing mill-out time, and further enhancing operational efficiency. The all-composite body produces fine, easily circulated cuttings that do not damage the casing or cement sheath, and the lightweight construction reduces transportation and handling costs compared to all-metallic plugs.

2. Three Configurable Versions (Standard / Ball Drop / Cage-Type)

Available in three main configurations to meet different operational needs, all sharing the same composite body and setting interface:

• Standard Bridge Plug: Replaceable plug assembly for balanced pressure isolation, supporting both positive and negative differential pressure - ideal for well testing, temporary abandonment, and applications requiring bidirectional pressure capability.

• Ball Drop Bridge Plug: Basic configuration that achieves positive differential pressure sealing by dropping a ball from the surface after anchoring - ideal for multi-stage fracturing and plug-and-perf completions.

• Cage-Type Bridge Plug: Replaceable cage assembly for positive differential pressure sealing after anchoring, with enhanced structural support suitable for complex well conditions including deviated wells, high-pressure formations, and challenging fluid environments.

This three-configuration approach allows operators to select the optimal version for each well without changing tool families, reducing inventory and training costs.

3. Multiple Setting Methods with Universal Quick-Change Sleeve

Flexible setting options to adapt to different well setups: wireline setting compatible with BAKER 10 and BAKER 20 wireline setting tools for rapid deployment without a work string; and tubing/coiled tubing hydraulic setting via surface pump pressure for wells where wireline is unavailable or unreliable. The universal setting sleeve and shear sub allow for quick plug replacement without disassembling the setting tool - simply change the plug and shear sub, and the same setting tool is ready for the next run. The reusable setting accessories further optimize operational expenses and reduce equipment inventory at the wellsite.

4. Superior Sealing & Casing-Friendly Anchoring

Equipped with high-performance sealing elements and cast iron slips that bite into the casing wall with minimal depth, ensuring reliable anchoring and leak-proof sealing even in P110 grade casings. The shallow slip bite depth minimizes casing damage - an important advantage for wells that may be re-entered or where casing integrity is critical. The slip cone design further enhances anchoring stability and prevents rotation during mill-out, working in conjunction with the LUG anti-rotation feature for maximum drill-out predictability. The sealing elements provide bidirectional pressure containment up to 10,000 PSI.

5. Cost-Efficient & Time-Saving

Fast drill-out capability (as low as 10 minutes, 10–20 minutes typical) reduces rig time and labor costs - a critical advantage in multi-stage fracturing programs where dozens of plugs may be drilled out in a single well. The composite material is lightweight, lowering transportation and handling costs, while the reusable setting accessories and universal quick-change sleeve further optimize operational expenses by reducing equipment inventory and changeover time. The all-composite body generates less metallic debris than cast iron plugs, reducing circulating time and the risk of debris-related issues during post-drill-out operations.

6. Wide Compatibility & Application Range

Designed to fit 4½" and 5½" casings (custom sizes available on request) and compatible with various casing grades including P110 and common grades, making it suitable for both vertical and horizontal wells in shale gas, oil, and geothermal projects. The plug's balanced pressure (Standard) and positive pressure (Ball Drop / Cage-Type) configuration options cover a broad range of operational scenarios - from well testing requiring bidirectional isolation to high-pressure fracturing requiring positive pressure sealing. Overall length ranges from 18.25" to 31" depending on configuration and size, with compact dimensions for easy deployment through wellbore restrictions.

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

Setting Process (Wireline Method)

1. The plug is connected to the BAKER 10 or BAKER 20 wireline setting tool via the universal setting sleeve and shear sub, and run into the wellbore on slickline/e-line to the target setting depth.

2. The wireline setting tool is fired, generating the setting force that drives the slip cone forward, expanding the cast iron slips outward to anchor against the casing wall, and compressing the high-performance sealing element to form a pressure-tight seal.

3. When the setting force reaches the predetermined value, the shear pins in the shear sub break, separating the setting tool from the plug. The LUG anti-rotation mechanism and slip cone lock the plug in place.

4. The setting tool is retrieved to surface, leaving the plug set and anchored. For Ball Drop configuration: a ball is dropped from surface and pumped down to seat on the plug's ball seat, enabling positive differential pressure sealing above the plug.

Setting Process (Tubing / Coiled Tubing Hydraulic Method)

1. The plug is connected to the work string via the universal setting sleeve and shear sub, and run to depth on tubing or coiled tubing.

2. Surface pump pressure is applied through the work string, actuating the hydraulic setting mechanism to expand the slips and compress the sealing element.

3. At the predetermined pressure, the shear sub releases, separating the work string from the plug. The work string is retrieved.

4. For Ball Drop configuration: the ball is dropped and seated as described above. For Standard or Cage-Type configuration: the plug is ready for operation immediately after setting.

Isolation Phase

Once set, the cast iron slips and compressed sealing element create a reliable pressure barrier. The Standard configuration supports both positive and negative differential pressure (balanced isolation), while the Ball Drop and Cage-Type configurations provide positive differential pressure sealing. The LUG anti-rotation design and slip cone maintain the plug's position and seal integrity during pressure cycling, fracturing, testing, or cementing operations. The plug is rated to 10,000 PSI and 300°F.

Drill-Out Phase

Once the operation is complete, the composite plug is milled out using a PDC bit on coiled tubing or drill pipe. The LUG anti-rotation design prevents the plug from spinning with the mill shoe, ensuring smooth, predictable cutting. The all-composite body (with cast iron slips only) produces fine, easily circulated cuttings. Drill-out time is typically 10–20 minutes depending on plug size and configuration. After drill-out, the well is ready for production or subsequent operations.

We adhere to strict quality control standards throughout the manufacturing process, from raw material selection to final assembly and testing. Our Series Composite Bridge Plugs are manufactured under an ISO 9001:2015 certified quality management system and comply with API Spec 11D1 standards for downhole isolation tools.

Quality Control Process

• Raw Material Inspection: Composite materials and cast iron sourced from approved suppliers with material test reports (MTR) verifying composition, mechanical properties, and temperature/pressure ratings. Composite material tested for tensile strength, compressive strength, chemical resistance, and drill-out characteristics. Sealing elements tested for hardness, tensile strength, and compression set.

• In-Process Control: Precision machining and molding with documented parameters; critical dimensions - slip tooth geometry, LUG anti-rotation profile, sealing element groove, slip cone fit, setting sleeve connection, and ball seat (for Ball Drop config) - inspected at first-article, in-process, and final stages.

• Finished Product Testing:

- Hydrostatic Pressure Seal Test: Each assembled plug tested at 10,000 PSI differential pressure with zero visible leakage

- Setting Function Test: Sample plugs set in test casing via both wireline (BAKER 10/20) and hydraulic methods to verify slip expansion, sealing element compression, and shear sub release

- Anti-Rotation Test: LUG design verified to prevent rotation under simulated drill-out torque

- Drill-Out Test: Representative samples drilled with PDC bits to verify drill-out time (target 10–20 min) and cutting characteristics

- Configuration Interchange Test: Standard / Ball Drop / Cage-Type assemblies verified for interchangeability on the same body

- Dimensional Inspection: 100% verification of critical dimensions 

Warranty

12-month warranty from date of shipment against manufacturing defects, with 24-hour technical support for setting procedure, configuration selection, and drill-out troubleshooting.

We offer comprehensive customization to match specific well conditions:

• Custom casing sizes beyond the standard 4½" and 5½" range

• Configuration selection: Standard (balanced pressure), Ball Drop, or Cage-Type

• Custom sealing element materials (HNBR, Viton, Aflas) for higher temperature or special fluid conditions

• Custom composite material formulation for special well conditions

• Custom slip material for special casing grades

• Setting tool compatibility options (BAKER 10/20 or equivalent)

• Custom overall length for restricted wellbore applications

• Custom color coding for configuration identification (standard green iso-drill finish) • OEM/ODM branding and custom packaging

• Bulk packaging for multi-well fracturing campaigns

Lead time for custom orders: 15–25 working days depending on complexity; sample evaluation units available before bulk orders.

1. Multi-Stage Fracturing

Ideal for isolating multiple zones during high-pressure frac operations, allowing targeted stimulation of each reservoir zone to maximize hydrocarbon recovery. The Ball Drop configuration is the standard choice for plug-and-perf multi-stage completions, with fast 10–20 minute drill-out reducing transition time between stages and overall completion duration. The universal quick-change setting sleeve allows rapid plug changes between stages, and the reusable setting accessories reduce equipment costs for high-stage-count wells. The LUG anti-rotation design ensures predictable drill-out even in long horizontal laterals.

2. Well Testing & Evaluation

Used to isolate specific well sections for pressure testing, fluid sampling, and reservoir evaluation, ensuring accurate data collection without cross-zone interference. The Standard configuration's balanced pressure isolation capability - supporting both positive and negative differential pressure - is particularly valuable for well testing where pressure may be applied from either direction. The reliable bidirectional seal ensures test pressure integrity, and the temporary barrier can be drilled out after testing to restore full wellbore access.

3. Temporary Well Abandonment

Provides a temporary barrier for well abandonment projects, ensuring safety and environmental compliance during idle periods. The composite construction offers long-term sealing integrity during the abandonment period, and when the well is ready for re-entry or permanent abandonment, the plug can be quickly drilled out in 10–20 minutes - significantly faster than cast iron alternatives. The Standard configuration's bidirectional pressure capability handles pressure fluctuations from either direction during the abandonment period.

4. Cementing Operations

Serves as a temporary flow barrier during primary and remedial cementing, preventing cement channeling and ensuring proper cement placement around the casing. The Cage-Type configuration, with its enhanced structural support, is particularly suitable for complex cementing operations in challenging well conditions. The plug can be set below the cement interval to provide a lower barrier, and the cast iron slips with shallow bite depth protect casing integrity during subsequent operations.

5. Open Hole & Cased Hole Operations

Suitable for both open hole and cased hole applications, including plug-back operations above water production or lost circulation zones. The versatile setting methods (wireline or hydraulic) allow deployment in both cased-hole and open-hole environments, and the three configuration options cover the range of pressure requirements encountered in these operations - from balanced pressure isolation for water shutoff to positive pressure sealing for lost circulation remediation.

Q: What are the three configurations and how do I choose?

A: The Series Composite Bridge Plug is available in three configurations, all sharing the same composite body and setting interface:

• Standard: Replaceable plug assembly for balanced pressure isolation supporting both positive and negative differential pressure. Choose this for well testing, temporary abandonment, and applications requiring bidirectional pressure capability.

• Ball Drop: Basic configuration for positive differential pressure sealing via a surface-dropped ball after anchoring. Choose this for multi-stage fracturing and plug-and-perf completions.

• Cage-Type: Replaceable cage assembly for positive differential pressure sealing with enhanced structural support. Choose this for complex well conditions including deviated wells, high-pressure formations, and challenging fluid environments.

All three use the same setting tools and can be changed by swapping the upper assembly - contact our engineering team for a configuration recommendation based on your well objectives.

Q: What is the LUG anti-rotation design and why is it important?

A: The LUG anti-rotation design is a unique mechanical feature that prevents the composite plug from spinning with the PDC mill shoe during drill-out. Without anti-rotation, a composite plug can rotate with the bit, resulting in uneven cutting, extended mill-out time, and potential casing damage from the rotating slips. The LUG design locks the plug against rotation, ensuring smooth, predictable cutting in the 10–20 minute target range and protecting casing integrity - a significant advantage over composite plugs without this feature.

Q: What is the difference between this Series Composite Bridge Plug and the standard Composite Bridge Plug?

A: The main differences are: (1) Configurations - the Series plug offers three versions (Standard/Ball Drop/Cage-Type) including a balanced-pressure Standard option, while the standard Composite Bridge Plug offers ball-drop and flo-back configurations; (2) Anti-rotation - the Series plug uses a LUG anti-rotation design, while the standard Composite uses a positive lock-up mechanism; (3) Temperature - the Series plug is rated to 300°F standard, while the standard Composite is rated to 400°F with custom HT options; (4) Setting - both support wireline and hydraulic, but the Series plug features a universal quick-change setting sleeve and shear sub for faster plug changes; (5) Body material - both are all-composite with cast iron slips. Contact our team for a detailed comparison and selection guide.

Q: How long does drill-out take and what equipment is needed?

A: Drill-out time is 10–20 minutes depending on plug size, configuration, and well conditions - with some sizes as fast as 10 minutes. A standard PDC bit on coiled tubing or drill pipe is used. The LUG anti-rotation design ensures the plug does not spin, and the all-composite body (with cast iron slips only) produces fine, easily circulated cuttings. The shallow slip bite depth minimizes casing damage during mill-out.

Q: What setting tools are compatible and how does the quick-change sleeve work?

A: The plug is compatible with BAKER 10 and BAKER 20 wireline setting tools (for wireline deployment), and can also be set hydraulically on tubing or coiled tubing using surface pump pressure. The universal setting sleeve and shear sub design allows the plug to be changed quickly - after one plug is set, the setting tool returns to surface, the used shear sub is removed, a new plug with new shear sub is connected, and the setting tool is ready for the next run without disassembling the setting tool itself. This reduces changeover time significantly, especially in multi-stage fracturing programs.

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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