Wells in the Permian Basin continue to increase in technical complexity and lateral length, testing the limits of traditional completion practices in unconventional wells. Coiled tubing has been the standard method for drilling out frac plugs in the basin but has mechanical limitations in extended-reach and high-pressure laterals. Due to the increasing well complexity operators have begun using high technology hydraulic completion units (HCU), also known as a snubbing unit, to drill out frac plugs in certain Permian Basin wells. By using the HCU in wells with longer laterals, higher pressures, and downhole uncertainty/complexity some of the additional risk can be mitigated. The HCU system can provide a reliable and cost-effective means to cleanout laterals in the Permian Basin while reducing mechanical risk. The purpose of this paper is to present case histories that illustrate the positive impact of the HCU on field operations. This paper will also detail the evolution of the HCU over time to its current state of the art stand-alone rigless system.

In conjunction with the industry and basin-wide paradigm shift to drilling and completing extended laterals, Matador Resources Company (the operator) made significant plans in 2018 that would focus activity toward wells with laterals greater than one-mile. One operational hurdle to overcome in this shift change was the effective execution of removing frac plugs and sand at increased depths during a post-stimulation frac plug millout. Utilization of coiled-tubing units (CTUs) had been proven to be a successful millout method in one-mile laterals, but not without risk. Rig-assisted snubbing units coupled with workover rigs (WORs) provided for less risk with higher pulling strength capabilities and the ability to rotate tubing, but would often require operational time of up to twice that of typical coiled-tubing unit millouts. The stand-alone, rigless Hydraulic Completion Unit (HCU) was ultimately tested as a solution and proved to alleviate risks in extended lateral millouts while providing operational time and cost comparable to coiled-tubing units. The operator has since performed post-stimulation frac plug millouts on ∼45 horizontal wells in the Delaware Basin using HCUs. The majority of these wells carried lateral lengths of over 1.5 miles. Results and benefits observed by the operator include but are not limited to the list below: 1.) Ability to safely and consistently reach total depth (TD) on extended laterals through increased snubbing/pickup force and the HCU's pipe rotating ability 2.) Ability to pump at higher circulation rates in high-pressured wells (>3,500 psi wellhead pressure) to assist in effective wellbore cleaning 3.) Smaller footprint which allows for the utilization of two units simultaneously on multi-well pads 4.) Time and cost comparable to a standard coiled-tubing millout, particularly on multi-well pads.

Completions operations, especially in modern day extended laterals, presents challenges related to tripping to total depth, applying weight down and pull up, and rotating. As dozens of stages in laterals exceeding 10,000 ft stepout have become frequent, numerous technologies have risen to assist with pushing the envelope for reliable completions operations in these long laterals. This paper examines a combination of three technologies that are more commonly being applied when drilling out frac plugs in long horizontals in the USA: hydraulic completion units, torque and drag software, and data acquisition systems. Coiled tubing units (CTU) have historically been used to drill out frac plugs in shorter horizontal shale wells for the last two decades, and where coil has mechanical limitations, Hydraulic Completion Units (HCU) have taken over drilling out frac plugs in the longer laterals of >10,000 ft. As the limits of drilling out frac plugs have been tested for HCUs, accurate real time data has enabled the crews to make the most of their equipment to reliably complete wells with longer and longer lateral sections. Torque and drag software modeling is a tool commonly used to predict axial force and torsional values during completions that result in the available hook load and the rotary torque requirements. The largest unknown in the planning phase is the appropriate friction factor to use for the upcoming well, with accurate friction factor prediction therefore the key to accurate prejob analysis. As of 2019 remote telemetry data acquisition systems (DAS) have been used on the HCUs, which has allowed key performance indicators (KPIs) to be automatically calculated. The program provides live feed to the service company and operator so that real time changes can be made if necessary. In addition to tracking KPIs in real time to provide the field crew positive or negative feedback, friction factors can be matched to predictive torque plots to identify trends prior to problems arising. Post-job analysis is needed to produce accurate predictive friction factors for future offset wells. The two main components to a successful post-job analysis are a software model that correctly represents the prior wellbore operations and accurate field data to compare with that model. Unfortunately, the software models in use are commonly limited by necessary assumptions with input data, such as rotary speed and tripping speed, and field data collected for comparison is often rudimentary. Experienced field personnel using engineering best practices can make use of current tools in combination to overcome the limitations commonly inhibiting accurate performance planning and predictive modeling. The inclusion of the DAS present on the HCU has greatly enhanced the accuracy and amount of rig data gathered, which can then be used in conjunction with operational procedures and torque and drag software to accurately plan and execute completions operations in the wellbore. Using data acquisition software, a constant stream of data was collected in one-second intervals in over two dozen wells. This system has the ability to measure both rotary speed and rotary torque, which are critical parameters when drilling out frac plugs. By removing these assumptions in the post-job analysis over a number of wells, a range of friction factors have been established for the Appalachian Basin in the Utica and Marcellus plays. The authors will present field data from two wells as representative case studies, along with the range of predictive friction factors established from 13 wells for the particular completions operations evaluated in the Permian and Appalachia plays. It is the goal of the authors to disseminate technical information on the methodology and practice of modeling wells post-job, calibrating friction factors, and establishing predictive ranges for successful use in future projects.