Patent Grant
11098567
Embodiments of the subject matter disclosed herein generally relate to a well completion process that involves perforating and/or fracturing operations associated with various stages of the well, and more specifically, to a process in which one or more stages of the well are perforated and/or fractured more than once so that two stages are overlapped.
After an oil and gas well 100 is drilled to a desired depth H relative to the surface 110, as illustrated in
Some of these steps require to lower into the well 100 a wireline 118 or equivalent tool, which is electrically and mechanically connected to the perforating gun assembly 114, and to activate the gun assembly and/or a setting tool 120 attached to the perforating gun assembly. Setting tool 120 is configured to hold the plug 112 prior to isolating a stage and also to set the plug.
The above operations may be repeated multiple times for perforating and/or fracturing the casing at multiple locations, corresponding to different stages 130, 132, etc. of the well. Note that in this case, multiple plugs 112 and 112′ may be used for isolating the respective stages from each other during the perforating phase and/or fracturing phase.
These completion operations may require several plugs run in series or several different plug types run in series. For example, within a given completion and/or production activity, the well may require several hundred plugs depending on the productivity, depths, and geophysics of each well. Subsequently, production of hydrocarbons from these zones requires that the sequentially set plugs be removed from the well. In order to reestablish flow past the existing plugs, an operator must remove and/or destroy the plugs by milling or drilling the plugs.
No matter how many plugs are used for separating each stage from a previous one, as shown in
Assuming good communication between each of the perforation clusters 140, 142 and the formation 106, the placement of fluid 124 within the stage may be uniform, i.e., the same amount of fluid 124 is pumped through each cluster 140, 142. A perforation cluster or cluster is understood herein to include perforation holes made with a cluster of shaped charges of a gun, into the well 102, to communicate a stage with the corresponding formation. Even if the placement of the fluid 124 into the formation is uniform through the clusters 140, 142, the conditions at the heel-ward (or uphole) cluster 140 are different from the conditions at the more toe-ward cluster 142, and the transport of the proppant material in the fluid 124 will not be the same. Note that the terms “heel-ward” and “toe-ward” herein are used with regard to the heel portion 102A and the toe region 102B of the well 102.
Further, the perforation holes in each cluster are subject to erosion as a function of time and the total proppant flow. Clusters with eroded perforations will take more fluid (and proppant) accelerating the effect, unless and until a more heel-ward cluster reduces the amount of fluid and proppant that the cluster is taking, by opportunistically taking the fluid first and reducing the available velocity and pressure. These conditions combine to produce clusters where the dominant treatment zone is often situated in the toe-ward clusters 142 of a stage, leaving the heel-ward clusters 140 relatively untreated. The reverse is also possible.
Diverters (chemical, conveyed solid, or perforation hole sized objects) are sometimes used to divert the flow from the dominant clusters to the less dominant clusters, with unknown effect. Once plug 112 is set, the heel-ward clusters 144 of the stage 132 are stranded and will never be properly treated, even after new perforation clusters 140, 142 are created and treated in the next stage 130.
Thus, the current fracturing methods fail to uniformly distribute the proppant material into the existing perforation clusters. For this reason, there is a need for a new perforation process that prevents such imbalanced proppant material within a given stage.
According to an embodiment, there is a method for fracturing a well casing and the method includes forming plural perforation clusters into a stage N associated with the well casing; fracturing the plural perforation clusters; forming a current stage N+1 by placing a plug within the stage N, to isolate a first subset of the plural perforation clusters from a second subset of the plural perforation clusters; and fracturing a second time the second subset, but not the first subset.
According to another embodiment, there is a method for fracturing a well that includes pumping a given fluid through plural perforation clusters formed into a stage N, which is associated with a first portion of a well casing; setting up a plug within the stage N, to close a bore of the well casing, so that a first subset of the plural perforation clusters is fluidly sealed off from a second subset of the plural perforation clusters; and pumping again the given fluid only through the second subset, but not through the first subset.
According to still another embodiment, there is a method for fracturing a well, and the method includes selecting a stage N that extends over a first portion of a well casing; perforating and fracturing the stage N; selecting a new stage N+1 that extends over a second portion of the well casing; and perforating and fracturing the stage N+1, where the first portion overlaps with the second portion and perforation holes made into the overlapped portion are fractured with a given fluid during the perforating and fracturing of the stage N and also during the perforating and fracturing of the stage N+1.
For a more complete understanding of the present invention, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:
The following description of the embodiments refers to the accompanying drawings. The same reference numbers in different drawings identify the same or similar elements. The following detailed description does not limit the invention. Instead, the scope of the invention is defined by the appended claims. The following embodiments are discussed, for simplicity, with regard to an oil and gas well having plural stages. However, the embodiments to be discussed next are not limited to an oil and gas well, but they may be applied to other types of wells.
Reference throughout the specification to “one embodiment” or “an embodiment” means that a particular feature, structure or characteristic described in connection with an embodiment is included in at least one embodiment of the subject matter disclosed. Thus, the appearance of the phrases “in one embodiment” or “in an embodiment” in various places throughout the specification is not necessarily referring to the same embodiment. Further, the particular features, structures or characteristics may be combined in any suitable manner in one or more embodiments.
According to an embodiment, a novel perf and frac method is introduced and this method is directed to a new type of staged unconventional well, where some of the stages may overlap. To overlap the stages, a plug for a subsequent stage may be positioned lower than at least one of the most heel-ward cluster of the previous stage, i.e., within that previous stage. The subsequent stage may be perforated so that the new perforation clusters are made only in the new part of the stage. However, in one application, it is possible to add perforation clusters in the overlap portion of the clusters or only in the previous stage. In one embodiment, the number of overlap stages can vary from two to the total number of stages. In other words, in a given well, it is possible to simultaneously have conventional and overlapped stages in any ratio and in any order. Various modifications to these steps may be implemented, as discussed later.
Prior to discussing the new method, some definitions related to the perforation clusters are believed to be in order.
With these clarifications in mind, an embodiment of the novel perf and frac process is now discussed with regard to
A gun 420 is then lowered into the bore 404 and shaped charges 420-I, which are distributed around the gun, are shot to generate the perforation clusters 410N+1-1, 410N+1-2, 410N+1-3, 410N+1-4, 410N+1-5, etc., each cluster having perforations 414-I, as illustrated in
However, the next plug 412N+1 is not placed at the location suggested in
After the perforation clusters are made for the N+2 stage, and the fracturing operation is completed, a corresponding plug 412N+2 is placed in the bore 404 to seal off the N+2 stage. The plug may be placed at an end of the stage N+2, as traditionally planned, or within the N+2 stage, according to an embodiment. This process can continue for the next stage N+3, with one or more of the perforation clusters made to overlap with the stage N+2 if the corresponding plug 412N+2 is placed within the stage N+2. In one embodiment, the corresponding plug 412N+2 is placed to not overlap the stages N+2 and N+3. Those skilled in the art, with the benefit of this disclosure, will understand that each new stage may be made to overlap or not with a previous stage. In one embodiment, it is possible to make a new stage to overlap with more than one previous stage. In this regard, note that a length of a stage along a longitudinal axis of the well may be in the orders of meters to tens of meters to hundreds of meters. For example, if a stage N is about 10 m, then the next stage N+1 may be made to overlap for 9 m with the stage N, and the next stage N+2 may be made to overlap for 9 m with the stage N+1 and for 8 m with the stage N, and so on. Further, the perforation clusters in a new stage N+1, that overlaps with the previous stage N, may be made to be interspersed with the perforation clusters of the previous stage, to partially overlap with the perforation clusters of the previous stage, or to be fully upstream of the perforation clusters of the previous stage.
With this novel configuration of overlapped stages, the following problem that might be encountered in the well may be solved.
If the plug 412N is placed within the stage N, as shown in
However, it is possible that after setting the plug 412N within the stage N, and sealing off a first subset 416N-1 of perforation clusters and leaving exposed to fluid communication with the fluid within the bore a second subset 416N-2 of perforation clusters, as shown in
A method for enlarging the diameter of the heel-ward perforating clusters in a given stage N, while the diameter of the toe-ward perforating clusters are maintained unchanged is now discussed with regard to
After the fracturing operation, in step 604, a corresponding plug 412N is setup in the well casing, to seal of a portion of the stage N, but not the entire stage N, as illustrated in
In step 608, part of the perforation clusters of the previous stage N and the perforation clusters of the new stage N+1 (if any is made) are simultaneously fractured with the proppant material, to increase a diameter of the perforation clusters of the previous stage N, as shown in
Various additional steps may be added to this method. For example, in step 606, the newly added perforation clusters may be added only to the previous stage N, or only to the current stage N+1, or to both stages. Some of the newly added perforation clusters may be matched to the previous perforation clusters.
In one application, the plug is not a solid plug that fully seals the bore of the casing well, but the plug has a mandrel or similar internal structure that provides a fluid communication channel between the previous stage N and the current stage N+1. For example, the plug can be a retrievable ball in place plug that uses a ball for fully sealing the current stage N+1 from the previous stage N. The ball may be a degradable ball, or a ball on a string. The plug may also be a standing valve plug. In fact, any type of plug may be used with this method. If a plug having an interior bore is used, it allows an immediate step down rate testing into the newly isolated perforation clusters of the current N+1 stage, to determine if additional perforating clusters should be added, or how many should be added. In yet another variation, a test packer could be incorporated into the tool string, and combined with the previous testing, to determine where the plug should be placed inside the well casing.
Frac plugs typically have a through hole which enables flow past the plug without a ball on a seat, so that wireline tool strings can be pumped down with the plug (but not ball) in place. With this well design, solid plugs (bridge plugs) could be used with slightly more risk (because no flow back operations can be performed with solid plugs), but much less cost. These plugs could be composite, hybrid of metal and composite, degradable or partially degradable.
In another variation of the method discussed herein, the number of overlapped perforation clusters in the current stage N+1 can be varied from zero to a total number of the perforation clusters in the previous stage N minus one. The hole size distributions or number of holes in the perforation clusters can be varied in the various stages to promote a toe dominated treatment for the successive stages.
Not all the stages in the well need to be overlapped. The configuration of the frac process can be designed to “reset” to a full un-overlapped stage every 3, 4, or “M”, stages, as the design parameters in step 606 may be successively changed. In other words, it is possible to have overlapped stages N, N+1, . . . , N+I, followed by traditional stages N+I+1, . . . N+I+J, followed by overlapped stages N+I+J+I, . . . N+I+J+K, where I, J, and K are any integers. Thus, in one embodiment, there is a mixture of conventional and overlapped stages, even without design parameters which would need to be reset. The needed to overlap stages could be determined by where the wireline string impacts sand in the well, which should occur at the perforations which took fluid and sand. In one application, overlapping stages could be targeted to specific portions of the well, based on well inclination, drilling plan, actual versus target depth, drilling correction zones, or geology. Thus, in this application, the selection of the locations where to have overlapped stages is based on one or more of these parameters.
The fracture treatment in the overlapped stages can be reduced or changed to control or limit (a) parent-child well interactions, (b) treating into natural fractures, (c) toe/heel dominance, while still maintaining fracture density. In this regard, note that the operator of the well could be aware of data, for example, seismic data that imagine the subsurface, that indicates various specific situations with regard to the well (e.g., natural fractures). For these situations, the operator of the well selects to make the overlapped stages and also to control what amount of treatment to apply to the overlapped stages to account for the existing data. For example, if there are natural fractures at the toe-ward part of a given stage, that stage may be overlapped for increasing the diameters of the heel-ward perforation clusters. Feedback from micro-seismic measurements, tracer or any other real time fracture imaging could be used to stop the fracture treatment of a stage, and trigger the next overlapping stage, limiting extensive fractures while preserving well fracture density. Feedback from pressure measurements that take place when the well is explored could be used in a similar way. Feedback from the step rate testing (flow versus pressure response) conducted after step 604 in the method could be used to determine whether new perforations need to be added. As a measure of economy, a treatment stage may be planned and executed in conjunction with each wireline run, no matter the outcome of placement or overlap achieved.
In one embodiment, the inter-stage plug acts as a positively set diverter, which is much more reliable compared to conventional diversion products since its precise location is known, and testing and feedback can determine whether it is necessary and whether the amount of diversion needs to be reduced by adding additional perforations. For this reason, there will be a lower cost to create more stages in a well.
Due to this overlapping stage technology, there will be a stage by stage feedback for tuning the stage design in real time. The resultant fracture network will be less sensitive to heel-biased dominance, as each heel-dominant stage can be corrected as discussed above with regard to
The novel technology discussed can be implemented in various ways in an actual well. A couple of those possibilities are now discussed. According to an embodiment, which is illustrated in
The method may further include a step of forming plural perforation clusters 410N+1-I into a current stage N+1 associated with the well casing 402, where the current stage N+1 is partially overlapped with the stage N. In one application, the current stage N+1 and the stage N share the second subset 416N-2 of the plural perforation clusters 410N-I.
The method may further include a step of fracturing simultaneously the plural perforation clusters 410N+1-I of the current stage N+1 and the plural perforation clusters 410N-I of the stage N. An overlap of the stage N and the current stage N+1 is defined by the second subset of the perforation clusters. In one application, one of the perforation clusters formed in the current stage N+1 is made to match a corresponding one of the perforation clusters formed in the stage N. In this application or another application, one of the perforation clusters formed in the current stage N+1 is made between two perforation clusters formed in the stage N. In this application or another application, a perforation cluster in the stage N or the current stage N+1 includes plural holes formed through the well casing to fluidly communicate a bore of the well casing with an exterior of the well casing.
In one embodiment, the step of fracturing a second time the second subset of the perforation clusters of the stage N increases a diameter of holes in the well associated with the perforation clusters. In this embodiment or another embodiment, the step of forming the plural perforation clusters in stage N includes lowering a gun into the well casing and detonated shaped charges of the gun to make holes through the well casing. In one application, the second subset 416N-2 includes one perforation cluster. In this or another application, the second subset 416N-2 includes one hole made in the well casing.
In another embodiment, as illustrated in
The plug defines a toe-ward end of a current stage N+1 and the current stage N+1 is associated with a second portion of the well casing and the second portion overlaps with the first portion of the well casing. In one application, the second subset 416N-2 of the plural perforation clusters 410N-I is located in an overlap portion of the first and second portions of the well casing.
The method may further include a step of forming additional plural perforation clusters 410N+1-I into the current stage N+1, in a part of the second portion that is not overlapped with the first portion, and/or a step of simultaneously pumping the given fluid into the second subset 416N-2 of the plural perforation clusters 410N-I and the additional plural perforation clusters 410N+1-I of the current stage N+1. The method may further include a step of setting up another plug 412N+1 at an upstream end of the current stage N+1, to fully close the bore of the well casing 402, so that all the plural perforation clusters 410N+1-I of the current stage N+1 are fluidly sealed off, a step of forming new plural perforation clusters into a new stage N+2, in a third portion of the well casing, which does not overlap with the second portion, and a step of pumping the given fluid through the new plural perforation clusters of the new stage N+2.
In yet another embodiment, as illustrated in
The disclosed embodiments provide a novel way to fracture plural stages in a well casing so that corrective action can be taken after a previous stage N has been fractured. With this technology, it is possible to fracture twice selected perforation clusters of a given stage, the first time when the given stage is fractured, and the second time when the next stage is fractured. It should be understood that this description is not intended to limit the invention. On the contrary, the embodiments are intended to cover alternatives, modifications and equivalents, which are included in the spirit and scope of the invention as defined by the appended claims. Further, in the detailed description of the embodiments, numerous specific details are set forth in order to provide a comprehensive understanding of the claimed invention. However, one skilled in the art would understand that various embodiments may be practiced without such specific details.
Although the features and elements of the present embodiments are described in the embodiments in particular combinations, each feature or element can be used alone without the other features and elements of the embodiments or in various combinations with or without other features and elements disclosed herein.
This written description uses examples of the subject matter disclosed to enable any person skilled in the art to practice the same, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the subject matter is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims.
| Number | Name | Date | Kind |
|---|---|---|---|
| 5273115 | Spafford | Dec 1993 | A |
| 20150144347 | Brannon | May 2015 | A1 |
| 20180245440 | Entchev | Aug 2018 | A1 |
| Number | Date | Country | |
|---|---|---|---|
| 20200300072 A1 | Sep 2020 | US |
| Number | Date | Country | |
|---|---|---|---|
| 62819948 | Mar 2019 | US |
