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This paper discusses the successful deployment of Multi-stage Fracturing (MSF) completions, composed of novel expandable steel packers, in high pressure, high temperature (HP/HT) horizontal gas wells. The 5-7/8" horizontal sections of these wells were drilled in high pressure, high temperature gas bearing formations. There were also washed-outs & high "dog-legs" along their wellbores, due to constant geo-steering required to keep the laterals within the hydrocarbon bearing zones. These factors introduced challenges to deploying the conventional MSF completion in these laterals. Due to the delicate nature of their packer elastomers and their susceptibility to degradation at high temperature, these conventional MSF completions could not be run in such hostile down-hole conditions without the risk of damage or getting stuck off-bottom. This paper describes the deployment of a novel expandable steel packer MSF completion in these tough down-hole conditions. These expandable steel packers could overcome the challenges mentioned above due to the following unique features: High temperature durability. Enhanced ruggedness which gave them the ability to be rotated & reciprocated during without risk of damage. Reduced packer outer diameter (OD) of 5.500" as compared to the 5.625" OD of conventional elastomer MSF packers. Enhanced flexibility which enabled them to be deployed in wellbores with high dog-leg severity (DLS). With the ability to rotate & reciprocate them while running-in-hole (RIH), coupled with their higher annular clearance & tolerance of high temperature, the expandable steel packers were key to overcoming the risk of damaging or getting stuck with the MSF completion while RIH. Also, due to the higher setting pressure of the expandable steel packers when compared to conventional elastomer packers, there was a reduced risk of prematurely setting the packers if high circulating pressure were encountered during deployment. Another notable advantage of these expandable packers is that they provided an optimization opportunity to reduce the number of packers required in the MSF completion. In a conventional MSF completion, two elastomer packers are usually required to ensure optimum zonal isolation between each MSF stage. However, due to their superior sealing capability, only one expandable steel packer is required to ensure good inter-stage isolation. This greatly reduces the number of packers required in the MSF completion, thereby reducing its stiffness & ultimately reducing the probability of getting stuck while RIH. The results of using these expandable steel packers is the successful deployment of the MSF completions in these harsh down-hole conditions, elimination of non-productive time associated with stuck or damaged MSF completion as well as the safe & cost-effective completion in these critical horizontal gas wells.
This paper discusses the successful deployment of Multi-stage Fracturing (MSF) completions, composed of novel expandable steel packers, in high pressure, high temperature (HP/HT) horizontal gas wells. The 5-7/8" horizontal sections of these wells were drilled in high pressure, high temperature gas bearing formations. There were also washed-outs & high "dog-legs" along their wellbores, due to constant geo-steering required to keep the laterals within the hydrocarbon bearing zones. These factors introduced challenges to deploying the conventional MSF completion in these laterals. Due to the delicate nature of their packer elastomers and their susceptibility to degradation at high temperature, these conventional MSF completions could not be run in such hostile down-hole conditions without the risk of damage or getting stuck off-bottom. This paper describes the deployment of a novel expandable steel packer MSF completion in these tough down-hole conditions. These expandable steel packers could overcome the challenges mentioned above due to the following unique features: High temperature durability. Enhanced ruggedness which gave them the ability to be rotated & reciprocated during without risk of damage. Reduced packer outer diameter (OD) of 5.500" as compared to the 5.625" OD of conventional elastomer MSF packers. Enhanced flexibility which enabled them to be deployed in wellbores with high dog-leg severity (DLS). With the ability to rotate & reciprocate them while running-in-hole (RIH), coupled with their higher annular clearance & tolerance of high temperature, the expandable steel packers were key to overcoming the risk of damaging or getting stuck with the MSF completion while RIH. Also, due to the higher setting pressure of the expandable steel packers when compared to conventional elastomer packers, there was a reduced risk of prematurely setting the packers if high circulating pressure were encountered during deployment. Another notable advantage of these expandable packers is that they provided an optimization opportunity to reduce the number of packers required in the MSF completion. In a conventional MSF completion, two elastomer packers are usually required to ensure optimum zonal isolation between each MSF stage. However, due to their superior sealing capability, only one expandable steel packer is required to ensure good inter-stage isolation. This greatly reduces the number of packers required in the MSF completion, thereby reducing its stiffness & ultimately reducing the probability of getting stuck while RIH. The results of using these expandable steel packers is the successful deployment of the MSF completions in these harsh down-hole conditions, elimination of non-productive time associated with stuck or damaged MSF completion as well as the safe & cost-effective completion in these critical horizontal gas wells.
Open Hole Multi Stage Fracturing (OH MSF) completion system technologies and Plug and Perf (P&P) technique are being utilized with the goal of increasing hydrocarbon production for years. However, due to unfavorable open hole well conditions, increased number of stages and limitations of open hole packers under challenging HPHT environments, some of OH MSF completions planned are converted to cemented liners. P&P is the only option for multi stage fracturing in the event of cemented liner completions. This paper discusses if cemented MSF can be an alternative to OH MSF completion systems as well as P&P and expands the technology portfolio for multi stage fracturing. The new cemented MSF completion system consists of a cementable hydraulic frac port opened by applying pressure in the first stage and multiple cementable fracturing ports for the next stages that are opened by dropping activation balls during rig-less fracturing operations. Stage zonal isolation is not dependent on mechanical, swellable or metal expandable packers and relies on cement behind the completion. Zonal isolation can be achieved with cement in the absence of gauged hole. The deployment of the lower completion is much less sensitive to the washed out or over gauged hole condition than that of an OH MSF system. Moreover, cement on the annulus ensures integrity of stage isolation while minimizing liner deformation and maximizing full well accessibility after multi-stage stimulation treatments. This was the first time a 15k psi pressure rated cemented multi-stage fracturing completion system was successfully deployed and stimulated through in the area. The implementation had qualified and field-tested the novel completion methodology which resulted in successful multi-stage stimulation operations. Production rate was enhanced in the well completed with the cemented MSF when compared with offset wells having OH MSF and P&P completions. The novel system without isolation packers and less string stiffness was easy to deploy and allowed for precise frac initiation point through continuous cement behind the liner. Compared to P&P, the cemented MSF system maximized the operational efficiency and cost saving by eliminating the need of wireline perforation and frac plug milling with CT. To address the challenges encountered in deploying OH MSF completions, cemented liner and P&P operations, it was necessary to develop a new completion strategy providing commercial production rates comparable to results achieved from OH MSF completions. This paper seeks an answer to whether cemented MSF completion system can be an alternative to OH MSF systems or P&P technique. Successful implementation of a cemented MSF completion that utilizes cementable sleeves capable of withstanding high fracturing pressures and harsh environments improves attending tight formations in an efficient and cost-effective manner and diversifies the efforts in exploiting tight HPHT formations.
Multi Stage Fracturing (MSF) completion technology with a true 15,000 psi pressure rating, Multi-Entry (ME), cementable system was developed for utilization in deep tight gas wells. The new completion system brings operational and design improvements to the MSF methods utilized for these types of wells. This paper discusses the details on the development of the novel system considering harsh well conditions, its multi-entry design for creating multiple fractures across each stage, and improvements compared to the traditional open hole MSF solutions. A detailed review of the requirements for the completion installation, activation, fracturing execution and expected performance metrics will also be covered. The new cemented MSF completion system consists of a cementable hydraulic toe sleeve and cementable fracturing ports. The toe initiator placed in the first stage is opened by applying pressure whereas multiple cementable fracturing ports in the remaining stages are opened by dropping a single size ball in each stage. Zonal isolation relies on cement behind the completion rather than mechanical, swellable or metal expandable packer as in regular Open Hole (OH) MSF systems. To verify the completion system suitability for the target application, a thorough design of the system components and qualification testing were needed. Collaborative approach, clear project scope definition and detailed review of the solution were key factors to ensure final product met expectations. Several wells completed and stimulated successfully with the new ME MSF system will be discussed. It is observed that the slim design, rotatable feature was mitigating the challenges, reducing the overall risk of deployment. In addition, stimulating of stages using a single ball per stage activating multiple sleeves in each stage, except for the first stage which was with cementable hydraulic sleeves, resulted with more efficient fracturing operations by reducing time, resources, and emissions. The 15K cemented ME MSF completion system provided a third MSF option to complete deep tight gas wells in addition to the current two methods of cemented liner and open hole MSF completions. It bridges the gap between the current systems by relying on the cement for zonal isolation and allowing multiple sleeves in each stage, imitating clusters used in Plug&Perf (P&P) operations. The system eliminates isolation packers compared to open hole completions and perforation, plug setting, plug milling when compared to P&P cemented liners technique in which wireline and coiled tubing interventions are required.
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