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A recent study projects that about 35,000 hydraulic fracture treatments will be pumped per year through 2025. This study also projects that 75 to 79% of all new gas production from the onshore lower 48 in the U.S. will be produced from wells that have been hydraulically fractured. Recognizing this, PTTC recently gathered together industry specialists to share their experience and technology insights in a workshop in Houston. This article highlights key insights. PTTC captured these presentations and will be making them available in the near future (watch
www.pttc.org for further details).
Of utmost importance, those completing low permeability marginal wells must recognize that it is engineering intensive. A basic hypothesis in hydraulic fracturing is that production is a function of effective fracture length and effective fracture conductivity. Accepting this, high viscosity fluids carrying high proppant concentrations should provide more stimulation than water fracture treatments PROVIDED the treatment stays within zone, the fracture face is not severely damaged and the fracture fluid breaks and cleans up properly. Several speakers noted that industry needs improved fluids (breakers) for reservoirs in the 200 - 250 °F range. Other areas needing attention are better completion methods for thick multi-zone intervals, log-core correlations in tight sands, better understanding of oriented perforating, rapid analyses of well performance of tight gas sands, and models for naturally fractured reservoirs. More field data collection, demonstration R&D projects and better technology transfer are part of the picture.
Building an accurate mechanical earth model is essential to hydraulic fracturing success. Logs provide important well data. Taken together, wellbore image and dipole sonic logs provide key information about natural fracturing and fracture orientation. It is critical that logs be calibrated with core data. Fortunately, key parameters in the mechanical earth model do not vary widely in a given geographic area, so one doesn't need to core extensively. The most important correlation to develop is the relationship between permeability and porosity as a function of lithology. The second most important correlation is to determine values of in-situ stress in each rock layer above, within and below the pay zones. One can and should make multiple modeling runs, playing with the variables to learn which are important and the effect they have. Post-treatment analyses help refine the mechanical earth model.
When it comes to treatment design, geomechanics tell you what you can achieve. Key parameters are stress, modulus and leak-off. Reservoir permeability tells you what you want to try to achieve. One can measure permeability with pre-frac Modified Fracture Injection Tests (MFIT). In MFITs, the formation is broken down, set volumes are injected at different rates, then the well is shut-in and pressure decline monitored.
It is "effective" fracture dimensions (length and width), not just created dimensions, that are important. Long fracs
that don't stay propped or open achieve nothing. Achieving and maintaining
conductivity in the
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Dimensionless conductivity (Fcd), a key design parameter,
is the ratio of the ability of a fracture to carry gas to the
well to the ability of the formation to feed gas into the
fracture. For conventional reservoirs it is widely accepted
that one should design to achieve Fcd of 2. For tight gas
sands one needs an extra margin of safety with the optimum Fcd
range being 8 to 10 to ensure cleanup. Data confirm that, when
permeability (k) is measured rather than just estimated,
modeling is more reliable with post-treatment production
agreeing much more closely with predictions, proving the point
that it pays to know permeability. Reprinted with permission. |
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fracture is essential. There are multiple factors that impact
conductivity, including gel residue, damaged proppant, formation fines and
degraded proppant. Just a 20% porosity reduction may result in a 60% loss in
permeability. Operators often finish off treatments with small volumes of high
proppant concentration, striving to achieve very high conductivity in the
very-near-wellbore region.
New evidence indicates that proppant pack porosity (and thus
conductivity) degrades with time. Conventional proppants are subject to
embedment and crushing, which creates fines. The larger the proppant, the higher
the rate of degradation. Data show that coating proppants with resins or surface
modifying agents reduces degradation.
In several areas, industry has moved to waterfracs rather than
gel fracs for tight gas sands. Some contend that this is not because waterfracs
give better results, but because waterfracs cost less and achieve production
comparable to underperforming gel fracs. If choosing treated water, there must
be some in-situ stress contrast, a vertical Fcd > 2 and some residual un-propped
fracture width. If selecting treated water, one has decided that fracture
conductivity is not important. One can use less proppant, which should be
smaller so it will be transported further. Many operators are moving back
towards conductivity, employing hybrid treatments with treated water and linear
gels.
Hydraulic fracture treatments are usually a major portion of well
costs, so operational attention is warranted. Know that potential problems are
compounded with large volume, high rate jobs mixed on-the-fly. Everything about
the treatment should be measured and recorded, and that means "physically"
measuring inventories during and after the treatment. Step-down tests can
quantify near wellbore friction (tortuosity/perforation friction). Minifracs
provide information on fluid efficiency, leakoff and fracture closure pressure.
Monitor pressure falloff after the treatment. Immediate flowback accelerates
fracture closure, which reduces undesirable proppant settling. It is common
practice to flow-back at 2 - 3 BPM. When gas starts coming back, choke size
should be reduced to maintain flowing
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bottomhole pressure at 50% of reservoir pressure.
Everyone knows it—there are sweet spots in any reservoir. Data
from multiple fields confirm the fact that two-thirds of cumulative production
comes from roughly one-third of the wells. To avoid spending too much on what
will be poor wells, how can one identify production potential prior to the
treatment? A tight gas reservoir can exhibit a permeability distribution
differing by two orders of magnitude. Log interpretation and core data to
accurately measure the porosity and permeability range in a well is critical.
Knowing that range, design a fracture treatment for the higher permeability
intervals.
BJ Services (BJ) has developed an Ultra-Lightweight Proppant (ULWP)
made of walnut hulls impregnated and encapsulated with resins. As most commonly
developed, this ULWP has an apparent specific gravity less than half that of
conventional sand-based proppants. Being lighter, this ULWP settles less and
travels further, which increases the propped area several fold. BJ reports that
over 1,800 wells have been treated with many being slickwater fracturing
applications employing near neutrally buoyant slurries. Performance data in
several basins and formations indicate significant increases in production even
though treatments used significantly less proppant.
A recent advance by Schlumberger is ThermaFOAM, a foamed CO2
base fluid using a synthetic polymer. ThermaFOAM CO2 fluids are
cleaner because lower polymer loading is possible and no crosslinker is
required. Faster cleanup leads to reduced time to sales, which adds to the
economic benefit. Out just a short time, more than 60 jobs have been pumped in
highly depleted to normally pressured reservoirs. Production data from Wilcox
and Olmos sand treatments show a marked improvement in productivity.
Schlumberger also described experience with its FiberFRAC technology. FiberFRAC
relies on a mechanical fiber-based network for proppant transport. This
mechanical system leads to longer effective fracture half-lengths. The
mechanical fibers degrade and disappear. More than 150 jobs were pumped in 2005.
Examples from the Cotton Valley in East Texas, Wilcox in north Mexico, Barnett
Shale and Jonah Field demonstrated definite productivity improvements.
cont. on page
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