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SPE-184824-MS

Holistic Approach to Engineered Diversion-Aided Completion Providing New


Method of Fracture Isolation

Kirk Bartko, Kenneth McClelland, Almaz Sadykov, and Sohrat Baki, Saudi Aramco; Mohamed Khalifa, Mohamed
Zeghouani, and John Davis, Halliburton

Copyright 2017, Society of Petroleum Engineers

This paper was prepared for presentation at the SPE Hydraulic Fracturing Technology Conference and Exhibition held in The Woodlands, Texas, USA, 24-26 January
2017.

This paper was selected for presentation by an SPE program committee following review of information contained in an abstract submitted by the author(s). Contents
of the paper have not been reviewed by the Society of Petroleum Engineers and are subject to correction by the author(s). The material does not necessarily reflect
any position of the Society of Petroleum Engineers, its officers, or members. Electronic reproduction, distribution, or storage of any part of this paper without the written
consent of the Society of Petroleum Engineers is prohibited. Permission to reproduce in print is restricted to an abstract of not more than 300 words; illustrations may
not be copied. The abstract must contain conspicuous acknowledgment of SPE copyright.

Abstract
In the current energy market, operators of unconventional assets must explore new methods that dramatically
reduce the cost of recovery per barrels of oil equivalent (BOE) without adversely affecting production.
As such, a number of technologies focusing on expanding completion thresholds and mitigating bypassed
reserves have recently come on the market. This paper discusses an engineered approach to utilize one such
technology. The approach taken is a holistic petrophysical analysis, coupled with a novel controlled pressure
pumping technique (CPP), and deployment of degradable diversion pills within each stage to maximize
fracture initiations and stimulated volume.
The industry has long assumed that flow-through perforations were a relatively predictable process, given
that little or no extrinsic evidence suggested otherwise. Recently, major advances in fiber optic technology,
performed during both stimulation and production, have demonstrated that flow is actually not equally
distributed. During pumping operations, there can be great temporal variation in casing exit points affecting
fluid flow, the addition of diversion creates further complexity to this already dynamic environment. To
resolve against variability an integrated approach was required. A progressive completion arrangement
aided by petrophysical analysis to define and select perforation cluster locations, a new diagnostic fracture
breakdown and propagation process to remedy the chaotic nature of initial flow distribution, and well-
defined diversion materials and processes to manage exit point discharge was implemented.
Wells in the Jafurah area are typically drilled with approximately 5,000 ft laterals. Over time the challenge
of improving cluster efficiency, optimizing cluster spacing, and increasing connected stimulated reservoir
volume to enhance long-term well productivity has led to several solutions being introduced, including
increasing the number of clusters per stage while consequently increasing the pumping rate and using
diversion technology.

Introduction
The development of unconventional resources (UR) in Saudi Arabia is an initiative to address and meet
the challenges of future energy demand at the local scale. The "de-risking" strategy for exploration and
development of the source rocks builds upon the experiences gained from North American analogues. The
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company addressed common completion challenges encountered in similar deposits and developed a road
map for testing potential technologies, which could maximize completions efficiency and well production.
The UR production engineering team studied intra-stage fluid diversion and cluster efficiency as a
challenge to be addressed to improve efficiency and cost. It was previously confirmed to have an impact on
well stimulation and production performance in other plays with the advancements in the diagnostic tools
of the horizontal well intervention operations, namely distributed acoustic sensing (DAS) and distributed
temperature sensing (DTS) (Wheaton et al. 2016; Ramurthy et al. 2016).
Available cluster contribution and production evaluation techniques identified having similar flow
diversion problems in the Jafurah unconventional carbonate source rock, which is currently under
exploration and development phase. The lateral section historically was primarily completed with 16
stages per lateral mainly utilizing the plug-and-perf technique with three, 1-1/2 ft length clusters per stage
considering transverse fractures development (Mulhim et al. 2014). Transition from three cluster to four
cluster stages was planned for gaining efficiency and maximizing contact with the reservoir.
The first well treated with four clusters was landed within homogeneous reservoir section without
significant dipping and geometrical spacing was considered with similar treatment design. The initial three
stages with an increased number of perforation intervals at the toe section resulted in screen outs and
subsequent wellbore clean out operations. A conservative design approach had to be applied with a reduction
of clusters to three only per stage. After gaining confidence, the number of clusters was increased back
to four clusters in one stage maintaining a conservative approach. The production log after the treatment
identified poor to none contributing clusters, and only one or two sets of perforations within the same stage
showed a significant contribution based on "flush" production evaluation, Fig. 1.

Figure 1Averaged cluster contribution from production logging passes with information on average per stage.

The total design rate for four cluster stages could not be proportionally increased because of completion
limitations with a 14% reduction in rate available for each perforation interval. Three clusters stages were
treated with average treating pressure of 11,762 psi at 54 bbl/min and four cluster stages were as high as
12,402 psi at 68.5 bbl/min in average.
It is a regular practice to correlate production logging results to stimulation parameters for completing the
evaluation. A non-contributing cluster could be considered as not being properly stimulated. In this case,
absence of the control on the downhole fluid flow behavior with limited-entry technique and improper fluid
distribution among the clusters were among the root causes for high treating pressures encountered while
injecting viscous fluids with the proppant into the near-wellbore region. Such an effect, available from total
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rate and surface treating pressure observations, could be related to increased friction pressures with higher
than recommended rates passing via accepting fluid intervals only. A high rate without capacity for proppant
admittance could lead to premature bridging of the proppant, unsuccessful treatments and unstimulated
lateral sections overall.
These results confirmed that upscaling completion and moving to more clusters per stage for gaining
efficiency and optimizing cost require the diversion techniques to ensure successful treatment and aim
for production improvement with better distribution of the fluid and proppant along the lateral with the
transverse fractures.
An available diversion technique with stimulating multiple fracturing cycles with diverter introduced
between the consequent fracturing treatments was considered for trial with the following successful criteria:

Successful surface delivery of the diversion pill.

Successful placement of subsequent cycles.

Positive indication of diversion as measured by an increase in pressure when the agent pill enters
the perforations and near wellbore zone.
Complete degradation of the material with no evidence of surface returns.

Positive indication from the production logging tool (PLT) and nonradioactive log that diversion
was achieved.

Reservoir Description
The targeted Jurassic source rocks are an organic rich carbonate mudstone. The Jurassic mudstones
deposited during the Middle to Late Jurassic time period are highly calcareous with extremely low
clay content (Al Duhailian 2016; Hakami and Inan 2016). Based on X-ray diffraction measurements
from cores and cuttings, calcite is the dominant component. Samples that exhibit higher porosity are
commonly associated with a high content of organics with average interconnected porosity of 9.67%. Matrix
permeability is up to 1,300 nano-Darcies (0.0013 md) from a limited number of the samples (Mulhim et
al. 2014). The high quartz content and low clay content is associated with low water saturation and very
high gas saturation. The "T" formation is subdivided into three zones identified by the density log. Zone 1,
located at the base, is represented by the highest organic content, with total organic (TOC) values reaching
up to 14%. Zone 2 has an intermediate quality, and Zone 3 represents the lean source rock, Fig. 2. Maximum
temperatures (Tmax) values in the area of interest correspond to the maturity window of wet gas to volatile oil.

Figure 2Variation of gamma ray and TOC content (modified from Momin et al. 2014).
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Arabian tectonic plate movement northward in recent geological history, colliding with the Eurasian plate
as well as the opening of the Red Sea, determines the stress regime in the area. Over pressured source rock,
and sonic data interpretation together with diagnostic fracture injection test to analysis the pressure decline,
confirmed strike-slip stress regime at the target interval with overburden stress providing an intermediate
value of the three principal stresses. Hydraulic fractures in such a stress regime are expected to propagate in
the direction parallel to H as in the case of normal stress regime. However, challenges with the breakdown
of different perforation clusters could be encountered with high laminations within the reservoir and non-
homogeneous properties of the layers, the possibility of bottom-hole pressure exceeding overburden stress
and development of a horizontal fracture component.

Geomechanical Model
Mechanical property tests were performed on selected core material to determine the anisotropic nature of
the rock. The tests indicated the Jafurah Basin has a medium degree of anisotropy with the static Young's
Modulus ratio of Eh/Ev of 1.65. The static Poisson's ratio is approximately 1.38.
Multiple diagnostic fracturing injectivity tests (DFITs) and mini-frac diagnostic tests were pumped to
estimate pore pressure, fracture closure pressure and fluid efficiency, formation characteristics and leakoff
coefficients. Table 1 summarizes the results of diagnostics and typical rock properties on one of the wells
in the area of the Jafurah Basin.

Table 1DFIT analysis results (Al-Mulhim et al. 2015).

Parameter Value Units

Young's modulus 3.8 Mpsi


Poisson's ratio 0.23 -
Shmin gradient 0.96 psi/ft
Shmax gradient 1.2 psi/ft
Pore pressure gradient 0.7-0.88 psi/ft

Completion Strategy
The Jafurah Basin wells average a total lateral length of 5,000 ft, which is based on operation constraints.
The horizontal section is typically completed with 4.5" Q-125 grade, 15.1 lb/ft cemented liner and floating
5.5" C-95 grade, 20 lb/ft tubing tie back with a 10,000 psi wellhead tree. All completion jewelry, except
the wellhead tree, are rated for 15,000 psi, Fig. 3. A wellhead isolation tool (WHIT) is required to allow for
pumping frac jobs while isolating wellhead components.
The Jafurah Basin horizontal wells were initially completed with 16 fracturing stages, perforation depths
were selected by integrating petrophysics, geomechanical earth model, image logs, cement bond logs and
casing collar location. The perforation strategy utilized three clusters with a separation of 60 ft to 80 ft. A
single cluster was used at the toe to initiate the first fracture stage and to pump the diagnostic fracturing
infectivity test to calibrate the reservoir properties. Figure 4 is a typical stage strategy based on a completion
quality log.
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Figure 3Current well completion design for initial wells (Al-Mulhim et al. 2014).

Figure 4Completion quality log with cluster spacing strategy identified (Momin et al. 2015).

Several fracturing strategies were tested to determine the operational efficiency, well performance, and
economics of the treatment. Initial results indicated a conventional crosslinked fracture treatment was the
preferred design. Crosslinked fracturing treatments became one of the preferred stimulation techniques,
mostly due to the success in reliability based on existing wellhead configurations. Table 2 summarizes a
typical fracture treatment applied in Jafurah.

Table 2Stimulation design summary.

Description Practice

Fluid per cluster 1,000 to 1,400 bbl


Proppant per cluster 100,000 lb
Maximum proppant concentration 4 to 6 ppa
Fracturing treatment rate 40 to 70 bbl/min
Proppant type 100-mesh sand, 40/70, 30/50 and 20/40 ceramic proppant

Several challenges and limitations were observed with the current completion strategy limiting the ability
to increase the perforation cluster density. Figure 5 provides examples of the current fracture strategies in
offset wells.
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Figure 5Current treatment strategy.

Challenges related to the equipment limitations are:

Wellhead configurations rated for 10,000 psi.


Fracture operations used WHIT to overcome this issue; however, this limited operation
efficiency between stages as extra time was required to rig up and down the WHIT.
Erosion of the upper section of tubing due to hanging of the WHIT and changes on the internal
diameter of the wellbore.
A pumping rate limitation of approximately 60 to 70 bbl/min to control surface pressure due to
4.5 x 5.5 tie back completion limitations.
Organic rich laminated formations with high stress close to overburden pressures causing high
breakdown pressures.

Candidate Well Selection and Technique Applied


The candidate well selection for the testing of increasing cluster required geosteering drilling of the lateral
section. The criterion was a lateral that landed in either Zone 1 or 2 but did not undulate between the two
layers. The goal was to drill the lateral heal in Zone 1 and allow the well to walk into Zone 2. Controlling
the well placement enabled the selection of the perforation clusters based on expected breakdown pressures
from the geomechanic properties along the lateral. Other factors considered for the cluster spacing design
were degree of stress shadowing, limited-entry pressures (approximately 400 psi), Fig. 6, and rock fabric
because of the transition zone between Zone 1 and Zone 2 rock.
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Figure 6Limited entry perforation pressure requirements

Conventional multi-cluster fracturing techniques rely on limited-entry effects or back pressure to ensure
adequate treatment coverage across each cluster. Typically, this is not sufficient to ensure each cluster
receives an optimal dosage of the stage treatment. Diagnostic studies have shown most fracturing treatments
do not initiate and propagate a dominant fracture from each of the designed perforation clusters. This fact has
been demonstrated with PLTs and micro-seismic mapping studies, which have shown that on average, only
50% to 60% of the performance cluster of a wells contributes significantly to production. This is in addition
to the geomechanical modeling work that has been consistently telling us that due to stress shadowing it is
very difficult to initiate interior fracture development, and diverter enabled sequential injection cycles are
necessary to enhance the initiation points and ultimate stimulated volume.
The intra-stage diversion technique uses multiple proppant cycles separated by diversion spacers to
fully stimulate each zone in a primary completion, improving fracture distribution and generating more
net pressure to fracture the entire spectrum of stresses encountered across the interval. Additionally, the
multi-cycle placement volumetrically stimulates each cluster, yielding more effective flowing fracture half-
lengths in connection with the wellbore. The technique places a series of proppant cycles over each zone
using engineered diversion spacers to temporarily isolate existing fractures, diverting fluid flow to new
areas following each completed proppant cycle (Loya and Lahman 2014).
Considering the completion limitations on maximum allowable pump rate and treating pressure, a
chemical diverting particulate was used as the primary means of isolation with a frac plug isolating the
stages. The material chosen is multi-modal, self-assembling (fuses together at temperature), self-removing,
and environmentally friendly, Fig. 7. The particulate is varied-sized (8 to 40 mesh) with a specific gravity of
1.29 gm/cm3 (Agashe 2014). The chemical diverter material is batched mixed using a secondary blender and
split ratio method is deployed to ensure proper density downhole. The advantages of deploying a diverter
include the following:

Maximized reservoir contact area for improved long-term production potential.

Enhance multizone limited-entry fracturing treatments such as plug-and-perf and sliding sleeve
techniques.
Enhanced slurry and proppant distribution, which can result in using less proppant per stage for the
same impact. The placement of highly conductive proppant packs in complex fracture networks.
A self-degrading and environmentally benign diverter material that shows a real indication of
diversion.
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Figure 7Self degrading particulate material used for temporary diversion

Fracture Design and Execution


The trial test in Well-Q7 called for eight stages with a gradual increase of clusters per stage with objectives
set for evaluating the next course of action. Evaluation of the diverter efficiency was based on pressure
response, NRT proppant and production logging responses. Table 3 presents a summary of the diversion
stages.

Table 3Planned diversion stages.

Stage Perforation Pill Volume Proppant Max Proppant


Cluster (bbl.) Stages Proppant mesh size
(PPA)

1, 2, 3 5 12 2 5 30/50
4, 5 6 12 2 6 30/50
6 7 12 2 5 30/50
7, 8 8 12 3 5 30/50

For the first two stages, five clusters with two cycles of proppant treatments per stage separated by an
intra-stage diverter to isolate the first stimulated cycle have been designed. Cluster distribution was arranged
to have lower stress toward the toe and higher stress toward the heel, Fig. 8.

Figure 8 Perforation cluster stress profile


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Screen out is primarily considered as a negative event in the unconventional industry. In this case,
although the first trial stage ended with the premature abortion of the operation because of high pressure
during the second cycle, it provided encouragement of the effectiveness of this diversion technique.
Increased treating pressures encountered in the second cycle were largely related to tighter rock in newly
broken intervals, which could not tolerate operational challenges and deviations from design. A conservative
approach for later cycles was recommended in the initial stages, it could be applicable in any other wells,
where such technique is applied.
During the execution of the second stage, the pressure response when the near wellbore (NWB)
biodegradable diverter was entering the perforations and formation was at lower magnitude and the net
pressure difference between the two cycles was minimal, Fig. 9. Even though low magnitude diversion was
observed, the second cycle continued to demonstrate new clusters contacted.

Figure 9 NWB diversion net pressure impact stage

The decision was made then for the next treatment stages to change the approach by choosing higher
stress clusters toward the toe and the lower stress toward the heel, Fig. 10.

Figure 10Perforation cluster stress profile

A very sharp increase on pressure was observed when the NWB biodegradable reached perforations; the
difference on net pressure response was substantial between the two cycles, indicating diverter constrained
flow paths and new clusters being stimulated, Fig. 11.
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Figure 11 Perforation cluster stress profile

After the execution of the first treatments and the evaluation of formation response to the diversion
and surface efficiency have been conducted, we were confident to target eight clusters with three cycles
separated by two diversion intra-stages.
Figure 12 is the stage where three proppant cycles separated with two NWB biodegradable diversion
intra-stages have been successfully placed into formation through eight clusters.

Figure 12Treatment plot.

The diverter's selection main objective of Well-Q7 was to optimize the stimulation parameters by
reducing the number of stages but keeping an identical number of clusters as in offset wells. Normally,
effective stimulation of a high number of clusters in the stage requires an increase in pump rate for proper
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diversion between the clusters; however, the existing pump rate was limited to 60 to 70 bbl/min in Well-Q7
due to completion limitations on tubing and liner size, and surface limitations due to the WHIT. Utilization
of a diversion technique allowed us to resolve the limitation on rate and meet the limited-entry perforation
friction requirements.
Reduction of the stages was achieved without compromising stimulated reservoir area and productivity of
the well. Three proppant cycles with eight clusters in the stage were placed successfully in six hours, Fig. 6.
Therefore, the possibility of improving the efficiency of the operations was confirmed by cutting the number
of intervention operations and thereby eliminating the rig up and down of the WHIT, reducing coil tubing
milling time by having less amounts of frac plugs in the lateral. Overall, the diversion technique should help
to accelerate the process of the entire unconventional completion operations of the Jafurah Basin.

Control Pressure Pumping


Control pressure pumping (CPP) is the process implemented to improve dominating fracture initiation and
is based on a rapid net pressure boost in a fracture geometry as it grows. The process is accomplished by
means of a specific designed rate variation procedure to achieve the optimal tensile opening mechanism.
Depending on specific area goals, CPP can be designed for a variety of stimulation fluid viscosities to
initiate predominant planar fracture growth or dilate more complex fractures and increase the intensity of
shear fracturing events that can increase the connection with the reservoir's matrix porosity system and
hydraulically connect various natural fracture systems. Benefits of the CPP technique include, but are not
limited to, the following:

Pressure dependent leakoff control

Net pressure optimization

Reduced screen out risk

Complex fracturing process control

Enhanced fracture initiation control for frac designs utilizing diverter systems

Control of surface pressure and lowering overall treating pressure

In the following field examples, Fig. 13, CPP was performed in conjunction with the NWB diverter
utilization to ensure the maximum number of clusters break down and maintain a constant impulse flow
velocity during the cycle to produce the most consistent NWB diverter intra-stage diversion effects. In
general, for multi-cycle scenarios CPP assists on creating a more predictable (and greater) stress contrast
envelope to manage exit point discharge while fracturing and diverting.
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Figure 13CPP sequence of events.

Evaluation
Table 4 shows the sequence that the nonradioactive traceable (NRT) proppant was pumped to evaluate
technology by combining production logging and NRT proppant logging data. NRT proppant is a near
wellbore evaluation technique that accurately identifies proppant placement. The NRT proppant pumped
during the stimulation treatment contains a high thermal neutron capture compound that is dispersed
throughout the proppant during the manufacturing process. This unique nonradioactive tracer eliminates
the need for radioactive tracers and does not degrade over time, thereby allowing logging operations to
be conducted throughout the life of the well. The pulsed neutron logging tool should be run before and
after performing the main stimulation treatment. The pre-stimulation pulsed neutron log, which will be
used as a baseline, should be from open hole logging of the lateral section. Baseline, when compared to
the post-stimulation pulsed neutron log, it should identify areas of depressed neutron response signifying
the presence of proppant.
SPE-184824-MS 13

Table 430/50 NRT proppant distribution.

Stage Number Number Number NRT Proppant NRT Proppant


of Clusters of Cycles Stage Amount Amount
per Cycle 1 per Cycle 2

1 5 2 25,000 20,000
2 5 2 20,000
3 6 2 25,000 25,000
4 6 2 25,000
5 6 2 20,000
6 8 3* 25,000 25,000
7 8 2 25,000 25,000
8 8 2 25,000 25,000

NRT proppant was used as tail-in (10%) of the stages to determine if proper diversion was achieved with
the total amount required up to 335 K-lb of 30/50 high strength proppant/NRT proppant. In some of the
stages, NRT was considered to be pumped in the last cycle only, to confirm with the production log that
clusters without NRT proppant were contributing.
The proppant distribution among all clusters was confirmed by the logging run to trace the 30/50 NRT
proppant, indicating the success of the diversion, Fig. 14. Track 8 indicates the presence of NRT by the
separation of the neutron response. Track 9 provides the contribution per cluster based from the PLT logs.
Both logs indicated good contribution between the perforation clusters.

Figure 14PLT and NRT distribution across the clusters

Conclusions
The success of the NWB biodegradable diverter was based on pumping pressure observations and post-
logging diagnostic, which provides near wellbore resolution. The volume into each cluster could not be
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assessed because there was no microsiesmic monitoring or DAS/DTS, which would have provided an
overall effectiveness of the diverter. Production response is not discussed in the paper; however, Well-
Q7 produced as expected indicating the reduction in fracture stages did not impair productivity. Based on
pressure data and near wellbore diagnostic tools the following conclusions can be made:

The controlled pressure breakdown appears to have broken down new perforations based on
pressure responses from the individual rate increases. The conservative (nonaggressive) design
should be considered as a contingency for subsequent stages.
The NWB biodegradable diverter and post-analysis indicated diversion took place downhole. The
conservative (nonaggressive) design should be considered as a contingency for subsequent stages.
The eight-cluster stage resulted in placement of proppant slurry into each perforation cluster.

The pulsed neutron log indicates proppant entry into the perforation clusters and transverse
fractures development.
The on-the-fly diverter injection procedure is recommended, considering maintaining near
wellbore conductivity rather than the low-split ratio method.
No operational complications resulted from pumping the NWB biodegradable diverter.

Further volume and placement optimization of the NWB biodegradable diverter will provide
greater success in spreading the proppant slurry among the perforation clusters.
Diversion technology can successfully reduce the number of stages and improve operation
efficiencies.

Acknowledgements
The authors would like to thank the management of Saudi Aramco for permission to publish the paper and
to the operational personnel on location for successfully performing the fracture treatment.

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