Thru Tubing Solutions drives growth through patented technologies reshaping downhole operations
Thru Tubing Solutions (TTS) was founded in 1997 by Andy Ferguson, who still serves as our president today. He started the company from the ground up, and we’ve grown significantly from those early days,” begins Cliff McKaughan, Senior Business Development Manager.
“Our core business supports the completion and production of horizontal oil and gas wells. After wells are fracked, in stages using bridge plugs, we’re brought in to remove those plugs and prepare the well for production. We do this using downhole motors deployed on either coiled tubing – a continuous length of tubing wound onto a spool – or conventional threaded pipe, depending on the well conditions, depth and pressure requirements.
“We also provide tubing-conveyed perforating (TCP) services, where we perforate the well casing to allow oil or gas to flow into the wellbore. In addition, we have patented technologies for hydraulic fracturing operations, including a diversion system that helps improve frac efficiency by redirecting fluid to untreated sections of the reservoir.
“Beyond our main service lines, we also carry out fishing operations, recovering equipment that has become stuck downhole. We work with operators of all sizes, from independent producers to major companies such as ExxonMobil and ConocoPhillips, helping them complete wells, clean out laterals and keep operations running efficiently.”
Before joining TTS, Cliff spent 30 years with Baker Hughes, starting in 1983 in Oklahoma City. He began his career in the field, running a wide range of tools and services, and over the years progressed through roles in operations, district management, sales, engineering support and leadership.
“My career took me from Oklahoma to northern Michigan, then to Baker Hughes’ headquarters in Houston, where I worked in engineering support and gained international experience, before eventually returning to the Mid-Continent region,” he shares. “That journey exposed me to virtually every aspect of the oil and gas industry, from drilling and completions to production operations, and gave me experience across a wide variety of well types and operating environments.
“I’ve now been with TTS for more than 14 years. I joined the company in a sales role and helped build the sales organization in the Mid-Con and South Texas markets. What started as a very small team has grown into a group of 17 and developing that team has been one of the most rewarding parts of my career.
“Having worked across so many areas of the industry, I enjoy sharing that experience with the next generation of professionals. Even after more than four decades in oil and gas, there’s always something new to learn but passing on knowledge and helping younger team members grow is something I find especially fulfilling.”
TTS has a team of around ten design engineers and more than a dozen drafters who work together to develop new technologies and refine existing tools.
“Many projects begin when an operator approaches us with a specific challenge in the field,” Cliff explains. “Our engineering team develops a solution, creates a prototype, tests it, and works closely with the customer to refine the design. At the same time, many of our best innovations originate internally, with engineers identifying industry gaps or opportunities to improve performance and then collaborating to bring new concepts to life.
“That culture of innovation has resulted in 187 patents, all developed in house. Our engineers are constantly developing new products, and because we have design, manufacturing and testing capabilities under one roof, we can move from concept to prototype remarkably quick: sometimes in less than a month.
“Once a tool has been tested, we deploy it in the field through our network of districts across the US, Canada and international markets. Real-world performance data is fed back into the development process, allowing us to make refinements before full-scale rollout. Combined with a rigorous quality-control system that can instantly flag and remove potentially defective components across our global operations, this enables us to bring innovative, reliable technologies to market faster than many larger competitors.”
One of TTS’ most significant recent innovations is Metal Max, an all-metal downhole motor designed to overcome the limitations of traditional elastomer-based systems.
“Historically, most downhole motors have relied on rubber elastomers, which can degrade in high-temperature environments or when exposed to aggressive chemicals and unfiltered fluids,” Cliff notes. “When those elastomers fail, the motor fails, and that means costly downtime for both us and the operator.”
Metal Max eliminates that vulnerability entirely. By replacing rubber components with a patented all-metal rotor and stator design, the motor can withstand extreme temperatures, harsh chemical environments and demanding operating conditions without sacrificing performance.
“With Metal Max, we’ve effectively removed one of the most common causes of motor failure,” he says. “Whether it’s a 200-degree well or a 500-degree geothermal application, the motor continues to perform. That’s a gamechanger for operators.
“We can’t build them fast enough. I believe that within the next few years, most of the motors we run will be all-metal designs. The performance, reliability and versatility of the technology have made it one of the most exciting products we’ve ever developed.”
The same engineering expertise has also enabled TTS to expand into specialized markets such as geothermal energy and gas storage. In geothermal wells, the company’s all-metal bottom-hole assemblies allow it to operate in temperatures of up to 600°F, while its patented inflatable isolation systems help gas storage operators safely repair surface equipment without introducing fluids into underground storage caverns.
Alongside Metal Max, TTS will also be investing heavily in a new system called Unplug. Unplug is designed to address one of the biggest challenges in modern completions: the need to run and then drill out bridge plugs after every frac stage.
“With Unplug,” Cliff elaborates, “we’re able to isolate and stimulate each stage without setting conventional bridge plugs in the wellbore. That eliminates a significant amount of intervention work, reduces risk and improves efficiency for operators. We’ve already completed several successful jobs, and we’re seeing growing interest from major operators. I believe it has the potential to fundamentally change how wells are completed and will be a major part of our future growth.
“We’re also investing in the future of well control. One area we’re focused on is developing more automated systems that can help manage well-control events while keeping personnel further away from the wellhead. Safety is always the priority, and these technologies have the potential to significantly reduce exposure to high-risk environments while improving operational response.”
The business continues to grow year after year, and Cliff is optimistic about the future. “I believe that growth is a direct result of our commitment to innovation,” he adds. “At TTS, we never stand still; we’re always looking for the next technology, the next tool and the next way to solve a problem for our customers.
“We’re particularly excited about opportunities in natural gas, geothermal and next-generation well designs, as well as helping operators maximize production from existing assets. As wells become longer and more complex, and energy demand continues to rise, the need for innovative downhole technologies will only increase.
“Just as importantly, we’re backed by a financially strong and stable parent company, RPC Inc., which gives us the confidence to invest in new technologies and take a long-term view of growth. We’ve maintained that approach through every market cycle,” he concludes, “and I don’t see that changing. From where I sit, the future for TTS is exceptionally bright.”