Solid-Expandable Liner System With Custom Composite Frac Plugs Enables Recovery of Lost Reserves in the Piceance Basin

Abstract

Summary Casing-integrity failure, whether through parted casing, leaky collars, or some other issue, may result in less-effective stimulation work caused by abandonment of the plug-and-perforate method and/or completing through a frac liner. In more-extreme cases, it could result in lost reserves below the casing-failure point. Modern technology has provided a cost-effective solution to this problem. In this case, the operator confirmed parted 4 1/2-in. production casing at 9,761 ft (Fig. 1) in their northern Piceance basin acreage. The operator would have to repair the parted casing to fracture the lower six zones of the well. The plug-and-perforate method for zonal isolation was required to effectively complete the 2,825-ft vertical pay interval. To complete the stimulation program, the goals were to repair the short section of damaged casing and restore pressure integrity to the well while maintaining a sufficient inner diameter (ID) to allow composite frac plugs to pass through the repair and set in the base casing's larger ID below the split. After a corrugated patch failed to provide casing integrity, the solution was a 3 1/2-in. single-joint solid-expandable system that was expanded downhole to cover and seal the parted 4 1/2-in. casing in conjunction with the use of custom-made composite frac plugs. The 30-ft, 3 1/2-in. solid-expandable high-pressure/high-temperature (HP/HT) liner system was deployed and expanded in a single trip. This system provided the required pressure integrity to withstand the fracturing pressures needed in this area. The 3.261-in. drift ID of the expanded-solid liner allowed the operator to run custom 3.06-in.-outer-diameter (OD) composite frac plugs below the repaired section and successfully complete the well. This installation was a success because the operator had essentially written off 63% of the well's reserves caused by the casing part occurring above a majority of the pay interval. The operator is now realizing full production from the entire well. Moreover, this single-joint solid-expandable liner technology coupled with the special drillable composite frac plugs can be used in any HP/HT formation to repair the common issue of damaged casing to allow plug-and-perforage completions to continue.