Novel Multi-Stage Fracturing Sand Control Technology to Improve Completion Efficiency, Early Production and Reduce Well Cost

Abstract

Abstract High pressure stimulation of tight sandstone formations is occasionally combined with flowback of proppant and formation sand during the onset of production. This is generally attributed to characteristics of unconsolidated sandstones and their response to high pressure hydraulic stimulation. This brings an additional challenge to openhole multi-stage completion systems that now require a filtration mechanism as part of the completion design, to introduce a sand exclusion technology alongside the multi-stage ball activated frac sleeves. A novel openhole multistage fracturing system was developed combining the operational efficiency of ball activated frac sleeves with sand control efficiency of multi-membrane filtration sand screens. This combination of technologies deliver a robust completion design and a unique intervention-less solution to enable stimulation at high pressures and provide sand exclusion on production. The system comprises of a series of incrementally sized high strength disintegrating frac balls to activate and close stimulation frac sleeves while simultaneously also opening production sand control screens. The design allows for several production sand control screens in one stage to maximize reservoir contact for unrestricted production. The system allows to efficiently complete the frac treatment and start sand-free production of the well without any intermediate manipulation of downhole tools with coiled tubing (CT) or wireline. This technology brings substantial value by not only early sand-free production, but also flexibility to add additional sand screens within the stage without compromising stage count. The intervention-less design of the tools eliminates the need for coiled tubing (CT) manipulation of downhole tools and hence associated high intervention costs. Keeping in mind the increased need of high-pressure stimulation for unconventional and tight reservoirs, the system is designed to 15,000 psi rating. The sand screens are designed to be isolated from stimulation pressure while maximizing inflow area without compromising on sand control. Further, to enable full efficiency, the system includes high-strength disintegrating frac balls to enable an early production of the well. This paper encapsulates the design, functionality, and development testing of the intervention-less multistage fracturing sand control system. This novel technology is designed keeping in mind operator challenges associated with high cyclic stimulation pressure on completion tools, undesirable well intervention and associated high production costs.