Extended-Time Conductivity Testing of Proppants Used for Multi-Stage Horizontal Completions

The American Petroleum Institute Recommended Practice 19-D (2018) is the current industry standard for conductivity testing of proppants used in hydraulic fracturing. Similar to previous standards from both the API and ISO, it continues the practice of measuring a "reference" long-term conductivity after 50-hours of time at a given stress. The fracture design engineer is then left to estimate a damage factor to apply over the life of the well completion based on correlations or experience. This study takes four standard proppants used for multi-stage horizontal well completions in North America and presents test data over 250-days of "extended-time" at 7,500 psi of effective stress. The API RP 19-D procedure was followed for all testing, but extended for 250-days duration for the four proppant types: 40/70 mesh mono-crystalline "White" sand, 40/70 mesh multi-crystalline "Brown" sand, 100 mesh "Brown" sand, and 40/70 mesh Light Weight Ceramic (LWC). The 7,500 psi stress condition was chosen to replicate initial stress conditions for a 10,000 feet deep well with a 0.75 psi/ft fracture gradient - typical of unconventional resource plays such as the Bakken formation of North Dakota or the Delaware Basin in west Texas. Results presented provide a measure of the amount of damage occurring in the proppant pack due to time at stress. To the authors’ knowledge, there has never been any extended-time conductivity data published for multiple proppant types over the timeframe completed in this study - despite the obvious need for this understanding to optimize the stimulation design over the full life of the well. Results for the four proppant types are presented as conductivity curves as a function of time for the 250-days of testing. Pack degradation is shown to follow a semi-log decline. Late time continued degradation for all materials is extrapolated over the life of a typical well (40 years), and compared to extended-time particle size distribution and crush data to explain the results observed. Extended-time data such as this 250-day study have never been published on proppants such as these despite the fact that fracture conductivity has a major impact on the productive life of a well and the ultimate recovery of hydrocarbons from the formation. The data presented should be of great interest to any engineer involved with completion designs, or reservoir engineers assessing the productive life and ultimate recovery in the formation since economic optimization is primarily driven by the interplay of fracture length/area with extended-time in-situ fracture conductivity.

Evaluating the Performance of Horizontal Multi-Frac Wells in a Depleted Gas Condensate Reservoir in Sultanate of Oman

The Saih Rawl gas condensate field has been producing for 20 years from multiple fractured vertical wells covering a very thick gross interval with varying reservoir permeability. After many years of production, the remaining reserves are mainly in the lowest permeability upper units. A pilot program using horizontal multi-frac wells was started in 2015, and five wells were drilled, stimulated and tested over a four-year period. The number of stages per horizontal well ranged from 6 to 14, but in all cases production was much less than expected based on the number of stages and the production from offset vertical wells producing from the same reservoir units with a single fracture. The scope of this paper is to describe the work that was performed to understand the reason for the lower than expected performance of the horizontal wells, how to improve the performance, and the implementation of those ideas in two additional horizontal wells completed in 2020. The study workflow was to perform an integrated analysis of fracturing, production and well test data, in order to history match all available data with a consistent reservoir description (permeability and fracture properties). Fracturing data included diagnostic injections (breakdown, step-rate test and minifrac) and main fracture treatments, where net pressure matching was performed. After closure analysis (ACA) was not possible in most cases due to low reservoir pressure and absence of downhole gauges. Post-fracture well test and production matching was performed using 3D reservoir simulation models including local grid refinement to capture fracture dimensions and conductivity. Based on simulation results, the effective propped fracture half-length seen in the post-frac production was extremely small, on the order of tens of meters, in some of the wells. In other wells, the effective fracture half-length was consistent with the created propped half-length, but the fracture conductivity was extremely small (finite conductivity fracture). The problems with the propped fractures appear to be related to a combination of poor proppant pack cleanup, low proppant concentration and small proppant diameter, compounded by low reservoir pressure which has a negative impact on proppant regained permeability after fracturing with crosslinked gel. Key conclusions from this study are that 1) using the same fracture design in a horizontal well with transverse fractures will not give the same result as in a vertical well in the same reservoir, 2) the effect of depletion on proppant pack cleanup in high temperature tight gas reservoirs appears to be very strong, requiring an adjustment in fracture design and proppant selection to achieve reasonable fracture conductivity, and 3) achieving sufficient effective propped length and height is key to economic production.

Impact of Delayed Flowback on Well Performance: Case Study

Due to a resource optimization and efficiency improvements, wells that are hydraulically fractured in the tight gas Barik Formation of the Khazzan Field in the Sultanate of Oman are often temporarily left shut-in directly following a large scale massive hydraulic fracturing stimulation treatment. Extensive industry literature has often suggested (and reported), that this may result in a significant direct loss of productivity due to the delayed flowback and the resulting fracture conductivity and formation damage. This paper will review the available data from the Khazzan Field address these concerns; indicating where the concerns should and should not necessarily apply. The Barik Formation in the Khazzan Field is an over-pressured gas-condensate reservoir at 4,500 m with gas permeability ranging from 0.1 to 20 mD. The average well after hydraulic fracturing produces 25 MMscfd and 500 bcpd against a wellhead pressure of 4,000 psi. A typical hydraulic fracturing stimulation treatment consists of 14,000 bbl of a borate-crosslinked guar fluid, placing upwards of 1MM Lbs of high conductivity bauxite proppant within a single fracture. In order to assess the potential production loss due to delayed flowback operations, BP Oman performed a suite of formation damage tests including core samples from the Barik reservoir, fracture conductivity considerations and dynamic behaviors. Additionally, normalized production was compared between offset wells that were cleaned-up and put onto production at different times after the hydraulic fracturing operations. Core tests showed a range of fracture conductivities over time with delayed flowback after using the breaker concentrations from actual treatments. As expected, enhanced conductivity was achieved with additional breaker. The magnitude of the conductivity being created in these massive treatments was also demonstrated to be dominant with respect to damage effects. Finally, a normalized comparison of an extensive suite of wells clearly showed no discernible loss of production resulted from any delay in the flowback operations. This paper describes in details the workflow and resulting analysis of the impact of extensive shut-in versus immediate flowback post massive hydraulic fracturing. It indicates that the impact of such events will be limited if the appropriate steps have been taken to minimize the opportunity for damage to occur. Whereas the existing fracturing literature takes the safe stance of indicating that damage will always result from such shut-ins, this paper will demonstrate the limitations of such assumptions and the flexibility that can be demonstrated with real data.

Experimental Study on Fracturing Fracture Deformation Mechanism of Shale Reservoir

After large-scale sand fracturing of horizontal wells in shale gas reservoir, fracturing fractures will deform in the production process. However, fracture deformation will lead to the decrease in fracture conductivity and then cause the decrease of gas well productivity. Therefore, in order to evaluate the fracturing fracture deformation mechanism of shale reservoirs, the shale proppant-supported fracture deformation evaluation experiments were carried out under different proppant types, particle sizes, sanding concentrations, and closure pressure conditions, respectively, and the variation curves of fracture width was calculated by a stereomicroscope under different experimental conditions. Then based on the experimental results, the fracture sensitivity factors and fracture deformation mechanism were analyzed, and the deformation mechanisms of fracturing fractures affected by proppant embedding and crushing were studied emphatically. The analysis results of fracture sensitivity factors indicate that the larger the particle size and hardness of proppant, the lower the sand concentration, proppant embedded on the shale rock surface. Moreover, the deeper the proppant is embedded, the faster the fracture conductivity decreases. In addition, the greater the closure pressure, the more serious is the proppant embedment, and the faster the fracture width decreases. The analysis results of fracture deformation mechanism show that, on the on hand, under variable closure pressure, the proppant with larger hardness and larger particle size is used for fracturing, and the proppant embedded in the fracture surface is the main cause of fracture deformation. However, if only the sand concentration of the proppant in the fracture is changed, the fracture deformation is jointly dominated by the embedding and crushing of the proppant. On the other hand, under constant closure pressure, the main mechanism of fracture deformation is that the proppant is embedded into the fracture surface when the closure pressure is low, but if the closure pressure is high, the main mechanism of fracture deformation is the crushing and compaction of proppant.

Combined Proppant Placement and Early Production Modeling Achieve Increased Fracture Performance in Ecuador's Oriente Basin

In the paper, we document one iteration of the continuous improvement of well performance undertaken in the Oriente Basin in Ecuador. In the past, it had been observed that well economics was sometimes degraded by the issues related to proppant flowback from hydraulic fractures. Proppant flowback resulted in extra costs from well cleanouts, pump replacement, and damage to fracture conductivity. After evaluation of proppant flowback cases using the combined modeling workflow that simulates fracture growth, proppant placement, and early production of solids and fluids, it had been proposed to modify fracture designs and well startup strategy. In this paper, we review the first results of implementation of these modifications in the field and evaluate the significance of improvements.

Development of Machine Learning Based Propped Fracture Conductivity Correlations in Shale Formations

Propped hydraulic fracturing is a stimulation technique used in tight formations to create conductive fractures. To predict the fractured well productivity, the conductivity of those propped fractures should be estimated. It is common to measure the conductivity of propped fractures in the laboratory under controlled conditions. Nonetheless, it is costly and time-consuming which encouraged developing many empirical and analytical propped fracture conductivity models. Previous empirical models, however, were based on limited datasets producing questionable correlations. We propose herein new empirical models based on an extensive data set utilizing machine learning (ML) methods. In this study, an artificial neural network (ANN) was utilized. A dataset comprised of 351 data points of propped hydraulic fracture experiments on different shale types with different mineralogy under various confining stresses was collected and studied. Several statistical and data science approaches such as box and whisker plots, correlation crossplots, and Z-score techniques were used to remove the outliers and extreme data points. The performance of the developed model was evaluated using powerful metrics such as correlation coefficient and root mean squared error. After several executions and function evaluations, an ANN was found to be the best technique to predict propped fracture conductivity for different mineralogy. The proposed ANN models resulted in less than 7% error between actual and predicted values. In this study, in addition to the development of an optimized ANN model, explicit empirical correlations are also extracted from the weights and biases of the fine-tuned model. The proposed model of propped fracture conductivity was then compared with the commonly available correlations. The results revealed that the proposed mineralogy based propped fracture conductivity models made the predictions with a high correlation coefficient of 94%. This work clearly shows the potential of computer-based ML techniques in the determination of mineralogy based propped fracture conductivity. The proposed empirical correlation can be implemented without requiring any ML-based software.

Fracturing Fluid Design: A Closer Look at Breaker and Surfactant Selection

Guar and its derivatives are the most commonly used gelling agents for fracturing fluids. At high temperature, higher polymer loadings are required to maintain sufficient viscosity for proper proppant carry and creating the fracture geometry. To minimize fracturing fluids damage and optimize fracture conductivity, it is necessary to design a fluid that is easy to clean up by ensuring proper breaking and sufficiently low surface tension for flow back. Therefore, breakers and surfactants must be carefully selected and optimally dosed to ensure the success of fracturing treatments. In this study, two fracturing fluids were evaluated for moderate to high temperature applications with a focus on post-treatment cleanup efficiency. The first is a guar-based fluid with a borate crosslinker evaluated at 280°F and the second is a CMHPG-based fluid with a zirconate crosslinker evaluated at 320°F. The shear viscosities of both fluids were tested with a live sodium bromate breaker, a polymer encapsulated ammonium persulfate breaker and a dual breaker system combining the two breakers. Different anionic and nonionic surfactant chemistries (aminosulfonic acid and alcohol based) were investigated by measuring surface tension of the surfactant solutions at different concentrations. The compatibility of the surfactants with other fracturing fluid additives and their adsorption in Berea sandstone was also investigated. Finally, the damage caused by leak-off for each fracturing fluid was simulated by using coreflooding experiments and Berea sandstone core plugs. Lab results showed the guar and CMHPG fluids maintained sufficient viscosity for the first two hours at baseline, respectively. The encapsulated breaker proved to be effective in delaying the breaking of the fracturing fluids. The dual breaker system was the most effective and the loading was optimized for each tested temperature to provide the desired viscosity profile. Two of the examined surfactants were effective in lowering surface tension (below 30 dyne/cm) and were stable for all tested temperatures. The guar broken fluid showed better regained permeability (up to 94%) when compared to the CMHPG (up to 53%) fluid for Berea sandstone. This paper outlines a methodical approach to selecting and optimizing fracturing fluid chemical additives for better post-treatment cleanup and subsequent well productivity.

Laboratory Measurements Mapping Heterogeneity and Variation of Poroelasticity for Improved Hydraulic Fracture Design in a Tight Carbonate Reservoir Onshore UAE

Reservoir X is a thin and tight carbonate reservoir with thin caprock that isolates it from an adjacent giant reservoir. An accurate geomechanical model with high precision is required for designing the optimum hydraulic fracture and preventing communication with adjacent reservoirs. The reservoir exhibits considerable variability in rock properties that will affect fracture height growth, complexity, and width and rock interaction with treatment fluids. The heterogeneity observed from the tight sections is further complicated by the variation of Biot's poroelastic coefficient, α, which is required for accurate assessment of the effective stresses. Laboratory testing was required to characterize the extensive vertical heterogeneity for key inputs in developing a geomechanics model. Approximately 120 ft of continuous core from an onshore field was provided for this study. The core material represented a potential tight carbonate reservoir interval and bounding sections. Heterogeneity mapping was performed from continuous core measurements from CT-imaging and scratch testing. CT-imaging provides an indication of the bulk density variation and compositional changes. Scratch testing provides a continuous measure of the unconfined compressive strength (UCS). Combining the two provides a means for accurate definition of rock thickness for dense, moderately dense, and lower density material coupled with corresponding compressive strength. Rock units were then subdivided based on these continuous properties for further geomechanics tests. Using log analysis combined with continuous UCS measurements from scratch testing, eight rock type classes were defined covering the target reservoir interval and bounding sections. This information was used for optimizing the sample selection process to characterize each identified rock unit. Routine core analysis measurements reveal significant vertical heterogeneity with porosity ranging from 0.1% to 18.1%. Similar variability was determined from elastic properties for each of the eight rock types. Quasi-static values for Young's modulus and Poisson's ratio determined at in-situ stress conditions ranged from 2.6 to 9.6 × 106 psi, and from 0.16 to 0.34, respectively. The Biot's poroelastic coefficient has a first-order impact on the calculated effective stress profile, which directly affects fracture stimulation model results. Testing from this study combined with previous measurements (Noufal et al. 2020, SPE-202866-MS) provides a unique correlation with porosity and bulk compressibility. In addition, rock-fluid compatibility was evaluated with proppant embedment/fracture conductivity tests. Results are dependent on a given rock type, exhibiting a wide range of fracture conductivity as a function of closure stress from 10 to 1000 md-ft. Embedment for all cases was low to moderate.