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Successful stage tool repair with Saltel Patch

Ensuring well integrity, enabling Fracturing the well, leaving sufficient ID for the largest frac ball, and withstanding 8,900 psi [613 bar] frac pressure

The context

The client well had a frac port that was stuck in the open position. To resume fracturing operations, a casing patch had to be set inside the well to isolate the stage tool and restore well integrity.

The stage tool was milled out to drift ID 3.794 in [96.39 mm], the Patch needed to leave access for a 3.375in [85.73 mm] ball, yet still withstand high fracturing pressures of 8,900psi for multiple fracs with 2,000 tons of proppant.


stage tool repair2 2Saltel Patch was to restore well integrity so the customer could continue fracing the 20 stage well program. The largest ball size required to pass our set patch measured 3.375in [85.73mm]


39.47ft long patch x 4.5in x 0.118in (reinforced)
Elastomer thickness 0.059in, RIH OD 3.504in

Saltel Patch Installation

stage tool repair1 1Saltel then ran a 4.5-in reinforced patch to seal the open frac port, taking just under 5 hours to anchor and fully set it. The remaining drift ID was 3.438 in [87.33 mm], allowing the largest frac ball of 3.375-in [85.73-mm] OD to easily pass the set patch.
After the patch was fully set, it was pressure tested to 25 MPa [3,600 psi] against the toe port for 15 min, enabling the fracturing operation to resume.
The patch saw 100 tons of proppant per stage for a total of 2,000 tons pumped past the patch. This job was a major success for the client because the well was stimulated without losing stages below the patch.


The patch was successfully installed across the milled out Stage Tool. It was set and drifted using our 83.82mm OD drift ring to ensure the patch was fully set without any restriction. It was then pressure tested to 25MPa prior to starting fracturing phase. All 20 stages below the patch were stimulated at 8,900 psi [613 bar] without issue and withstood the high pressures and pump rates without leaking nor bursting.


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