Automated Plug-And-Perf Decreases Operational Risk and Improves Conveyance Efficiency

Abstract

Abstract Across upstream oil & gas operations, automation continues to be an increasingly important way to reduce risk and improve efficiencies, even for complex tasks historically requiring close human attention. Traditional manual processes are prone to higher inherent risks and inefficiencies, leading to unplanned non-productive time and cost overruns. However, the integration of advanced technologies such as robotics, closed-loop systems, and digital twins has paved the way for automated systems that are revolutionizing the industry. Within unconventional completions, wireline conveyed perforating or "plug and perf" jobs are a critical part of the hydraulic fracturing operation. A typical plug-and-perf job requires 6 or more individuals to convey the perforating gun string via wireline winch and pump down units over the course of a multi-well completion. This operation requires focus from all personnel involved since variable downhole conditions can cause costly unplanned events such as pre-set plugs or pumped-off tool strings downhole. These events result in unplanned well interventions such as coil tubing fishing jobs, which can be extremely costly. Natural inconsistencies introduced from different personnel conducting the operation also leads to variation in job efficiency. Halliburton has developed a novel system that takes real time data from the downhole tool string, the wireline winch, and the pumping units on location to feed a closed-loop system to convey perforating gun strings safely and efficiently within a wellbore. The system enables the winch and pumps to respond in real-time to variable downhole conditions and also predicts tool motion ahead of the string and continuously updates a forward-looking model using a digital twin. This method reduces the risk of unplanned events like pre-set plugs and pumped-off tool strings. Use of automated plug-and-perf has demonstrated up to a 12% faster run time while using less fluid than the same operation run manually. This paper highlights the benefits of automating the complex and manual task of pump-down perforating, including the reduced risk of unplanned well interventions, improved operations efficiency, and fluids consumption optimization. It has been demonstrated that all of these lead to decreased costs for both service company and operator, based on deployments in both the Permian and Denver-Julesburg Basin of North America. The use of automated perforating operations leads to a safer and more productive oil and gas industry, where human expertise is augmented by technology to achieve better outcomes.