Effectively stimulating multiple pay zones using separate fracturing treatments can be costly and time consuming. By contrast, multistage fracturing is a widely used technique that offers the advantage of stimulating significant portions of the reservoir by fracturing through multiple perforations simultaneously. While the multistage fracturing method known as "plug and perf" has been proven to be an effective method for developing unconventional resources, it presents the challenge of achieving even proppant distribution to all perforation clusters during each stimulation stage.It is commonly assumed that the plug and perforate multistage fracturing technique provides the planned fluid and proppant distribution among the fractures that are simultaneously taking fluid during pumping a single stage. However, parameters, such as the reservoir properties, fluid rheology, and proppant characteristics have demonstrated a strong influence on the actual proppant and fluid distribution into the various perforations.Field data indicates, in many cases, that some of the clusters do not contribute to production. This indication supports the hypothesis that actual proppant and fluid distribution along the stimulated clusters might be different from the assumed uniform distribution. Some believe that the amount of proppant appears to be heavily weighted toward the end of the perforated interval, which results in uneven proppant distribution. Empirical data as well as laboratory tests have yet to be challenged against the few studies that exist. This paper presents a first-of-its-kind large-scale investigation that was conducted to study proppant distribution among separated perforations along a horizontal interval. These experiments closely simulate any single stage during the plug-andperforate fracturing process. The effect of various fluid specific gravities, fluid viscosities, proppant specific gravities, proppant sizes, and slurry flow rates were investigated while keeping outside-casing parameters constant. The various aspects of proppant and fluid flow through a perforated interval are discussed. The experimental efforts discussed in this paper create a better understanding of fluid and proppant behavior in this widely used fracturing process to help achieve maximum efficiency.
Multistage hydraulic fracturing has become the key technology for completion of horizontal and vertical wells. The perf and plug method is the most commonly used staging method. In each stage, multiple perforation clusters are used, attempting to create a separate transverse fracture at each cluster. How these clusters are placed can significantly affect both short-and long-term production performance. Simultaneous creation of multiple fractures is a cost-effective and time saving method for stimulating both vertical and horizontal wells. Multistage fracturing is an effective method in terms of completion efficiency; however, achieving even proppant distribution to each cluster is an intricate task that proves to be challenging within the industry.Numerical simulations predict uneven proppant distribution of the fluid streams entering different perforation clusters. Field data indicates, in many cases, that some of the clusters do not contribute to production. This led to hypothesizing that actual proppant and fluid distribution along the stimulated clusters can differ from the assumed uniform distribution. However, with respect to limited-entry frac design, the proppant distribution among the different perforations is assumed to be the same as the fluid distribution. Until recently, this assumption remained unchallenged. This paper presents extensive study and investigation of proppant transport in different perforation clusters within a single stage by using computational fluid dynamics (CFD) techniques. Effects of varied fluid and proppant specific gravity, viscosities, proppant sizes, and slurry flow rates were analyzed while maintaining outside-casing parameters constant. Validation of empirical proppant transport CFD simulation results are compared to experimental test data. This is helpful to gaining a better understanding of fluid and proppant behaviors in multi cluster fracturing processes to achieve maximum efficiency.The results of the study indicate that proppant transport can be accurately modeled when the effects of single particle settling, density driven flow, particle velocity profiles, and slurry rheology are all considered. The investigation demonstrates that CFD is an effective tool for optimizing proppant distribution among perforation clusters and enhancing production.
Multistage hydraulic fracturing has become the key technology for completing horizontal and many vertical wells. In horizontal wells, the perf-and-plug method is the most commonly used staging method; in each stage, multiple perforation clusters are used to create separate transverse fractures at each cluster. How these clusters are placed can significantly affect a well's short- and long-term production performance. The simultaneous creation of multiple fractures is a cost effective and time saving method for stimulating both vertical and horizontal wells. Multistage fracturing is an effective method from the perspective of production, but the challenge of achieving even proppant distribution to each cluster is an intricate task for the industry. Numerical simulations predict uneven proppant distribution for the fluid streams entering different perforation clusters. Field data indicates that, in many cases, some of the clusters do not contribute to production. This led to hypothesizing that actual proppant and fluid distribution along the stimulated clusters might be different from the assumed uniform distribution. However, in limited entry fracture design concept, the proppant distribution among the different perforations is assumed to be the same as the fluid distribution. Until recently, this assumption remained unchallenged. This paper presents an extensive study and investigation of proppant transport in different perforation clusters within a single stage by using computational fluid dynamics (CFD) techniques. The effects of varied fluid and proppant specific gravity, viscosities, proppant sizes, and slurry flow rates were analyzed while keeping outside-casing parameters constant. Validation of empirical proppant transport CFD simulation results are compared to experimental test data. This is helpful to better understand fluid and proppant behaviors in multicluster fracturing processes to help achieve maximum efficiency. The results of the study indicate that proppant transport can be accurately modeled when the effects of single particle settling, density driven flow, particle velocity profiles, and slurry rheology are all considered. The investigation shows CFD is an effective tool for optimizing proppant distribution among perforation clusters and enhancing production.
Multistage hydraulic fracturing has become the key technology for completion of horizontal and vertical wells. The perf and plug method is the most commonly used staging method. During each stage, multiple perforation clusters are used, attempting to create a separate transverse fracture at each cluster. How these clusters are placed can significantly affect both short-and long-term production performances. Simultaneous creation of multiple fractures is a cost-effective and time saving method for stimulating both vertical and horizontal wells. Multistage fracturing is an effective method in terms of completion efficiency; however, achieving even proppant distribution to each cluster is an intricate task that can be challenging within the industry.Numerical simulations predict uneven proppant distribution of the fluid streams entering different perforation clusters. Field data indicates, in many cases, that some of the clusters do not contribute to production. This led to hypothesizing that actual proppant and fluid distribution along the stimulated clusters can differ from the assumed uniform distribution.This paper presents an extensive optimization study and investigation of proppant transport in different perforation clusters within a single stage using computational fluid dynamics (CFD) techniques. Effects of proppant and fluid properties (e.g., variable mass flow rate, variable proppant and fluid densities, and viscosity of the fluid) were analyzed, while maintaining outside-casing parameters constant. Validation of empirical proppant transport CFD simulation results are compared to experimental test data.The CFD results indicate that proppant transport can be accurately modeled when the effects of single particle settling, density driven flow, particle velocity profiles, and slurry rheology are all considered. Understanding the behavior of proppant and achieving more even proppant distribution among perforation clusters can help the industry. The investigation demonstrates that CFD is an effective tool for optimizing proppant distribution among perforation clusters and enhancing production.
Fracturing treatments often require massive volumes of silica sand. This sand must be unloaded from transport vehicles into proppant storage vessels, conveyed from the storage vessel to the fracturing blender, and mixed with fluid before being pumped down hole. Silica dust becomes airborne during this process, and onsite personnel can be exposed to that silica dust.In addition to posing a potential health risk if not handled properly or if personal protective equipment (PPE) is not worn, the silica dust can also negatively affect the fracturing equipment. It can lead to premature wear and failure of high-value capital equipment. For example, the dust increases the frequency of engine air filter changes and can plug radiator cores, reducing cooling capacity. Additionally, silica dust is highly abrasive and can cause premature wear on cylinders, bearings, gear sets, shafts, and other moving parts.Vacuum style dust collectors for capturing airborne silica have recently been introduced on some fracturing sites. Personnel exposure to respirable crystalline silica can be reduced and the negative effects on equipment minimized when using these dust collectors. However, one challenge introduced by the use of the collector is the need for packaging and disposal of the captured dust. This paper discusses an apparatus and ergonomic method for packaging and disposing of the dust once it is removed from the air. The apparatus is composed of a plenum chamber formed in a funnel or a frustum configuration that discharges into a distribution assembly. The distribution assembly includes a number of individual chutes, each equipped with a circular collar at the outlet, facilitating the attachment of dust collection sacks. The plenum chamber, distribution chute assembly, and individual dust collection sacks are supported by a frame assembly. This apparatus is used to package the material exiting the dust collector in easily transportable containers.
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