Evidence of Significant Casing Erosion Damage Caused by Leaking Frac Plugs During Stimulation's Leads to Uncertain Proppant Distribution Results

Abstract

Abstract Technology to interrogate perforations to quantify cluster efficiency in limited entry, plug and perf completions has improved in operational efficiency, image quality and quantity. The entire pipe wall of the lateral is now visually imaged, and the discovery of significant casing erosion damage caused by leaking frac plugs during stimulations is easily observable, often multiple times in the same well. The effect of a breached casing with significant erosion between stages could potentially divert proppant from the intended perforation targets leading to reduced cluster efficiency and uncertainty of proppant distribution results. Video images have been used for several years to evaluate proppant distribution. The recent introduction of array side-view camera technology now provides highly detailed images of the full 360 circumference of the wellbore over extended intervals. Image logging methods for unconventional wells have changed from capturing a limited number of images of individual perforations through a small ‘spy hole’ to a complete panoramic view of the entire wellbore. Perforations, connections and everything in between can be efficiently imaged and analysed. Enhanced processing methods have additionally improved visualization of results and allowed quantification of areas of interest with image-based dimensioning. Greatly enhanced borehole image coverage has allowed the discovery of unintended interactions that can be very detrimental to fracture treatments. Evidence of these unwanted effects that were previously difficult to diagnose are now uncovered during routine fracture diagnostics. Evidence includes Erosion at plug setting depths has been observed in a relatively high proportion of wells Multiple casing breaches have also been observed in some wells with as many as 35% of plug setting depths subject to this issue The areal extent of erosion at plugs has been measured in the range of 10% of the casing circumference up to 100% full parting While the exact effects on the fracture treatment of potentially large volumes of fluid and proppant being diverted away from their intended target has not yet been quantified the catastrophic effect on well integrity is very clear. Examples, analysis methods, results, primary conclusions, and other relevant findings are discussed in detail. The technology we discuss is undoubtedly helping raise awareness in the industry of the potential extent of this previously under-diagnosed issue. Increased awareness and improved understanding of the issue will lead operators to better equipment selection, enhanced procedures and ultimately more productive and profitable wells. Hydraulic fracture performance will improve while cases of compromised well integrity will decline.