HF2D FRAC DESIGN SPREADSHEET April 2001 (Updated May 30, 2006) Dr Peter P. Valkó Associate professor Harold Vance Department Petroleum Engineering Texas A&M University HF2D Page 1 TABLE OF CONTENTS 1 EXECUTIVE SUMMARY .......................................................................................... 4 2 DATA REQUIREMENT ............................................................................................ 5 3 CALCULATED RESULTS ....................................................................................... 8 4 THEORETICAL FRACTURE PERFORMANCE..................................................... 10 5 SUGGESTED DESIGN PROCEDURE BASED ON OPTIMAL PSEUDO-STEADY STATE PERFORMANCE ....................................................................................... 20 6 SAMPLE RUNS...................................................................................................... 27 NOMENCLATURE ................................................................................................. 36 CASE STUDIES ..................................................................................................... 38 HF2D Page 2 1 EXECUTIVE SUMMARY The HF2D Excel spreadsheet is a fast 2D design package for the 2D design of traditional (moderate permeability and hard rock) and frac&pack (higher permeability and soft rock) fracture treatments. Currently it contains the following worksheets: Traditional design with PKN (Perkins-Kern-Nordgren) model TSO (tip screen-out) design with PKN model Design with CDM (Continuum Damage Mechanics) version of the PKN model The unique feature of this design package is the logic it is based on. The design starts from the amount of proppant available. Then the optimum dimensions of the fracture are determined. Finally, the treatment schedule is found which will realize the optimum proppant placement. If the constraints do not allow optimum placement, a sub-optimal placement is designed. The results include fluid and proppant requirements, injection rates, added proppant concentrations (that is the proppant schedule) and additional information on the evolution of the fracture dimensions. HF2D Page 3 2 DATA REQUIREMENT The following table contains the description of the input parameters. Input Parameter Remark Proppant mass for (two wings), lab This is the single most important decision variable of the design procedure Sp grav of proppant material (water=1) For instance, 2.65 for sand Porosity of proppant pack The porosity of the pack might vary with closure stress, a typical value is 0.3 Proppant pack permeability, md Retained permeability including fluid residue and closure stress effects, might be reduced by a factor as large as 10 in case of non-Darcy flow in the frac Realistic proppant pack permeability would be in the range from 10,000 to 100,000 md for in-situ flow conditions. Values provided by manufacturers such, as 500,000 md for a “high strength” proppant should be considered with caution. Max prop diameter, Dpmax, inch From mesh size, for 20/40 mesh sand it is 0.035 in. Formation permeability, md Effective permeability of the formation Permeable (leakoff) thickness, ft This parameter is used for Productivity Index calculation (as net thickness) and in calculation of the apparent leakoff coefficient, because it is assumed there is no leakoff (and spurt loss) outside the permeable thickness. Well Radius, ft Needed for pseudo skin factor calculation Well drainage radius, ft Needed for optimum design. (Do not underestimate the importance of this parameter!) Pre-treatment skin factor Can be set zero, it does not influence the design. It affects only the "folds of increase" in productivity, because it is used as basis. Fracture height, ft Usually greater than the permeable height. One of the most critical design parameters. Might come from lithology information, or can be adjusted iteratively by the user, to be on the order of the frac length. Plane strain modulus, E' (psi) Defined as Young modulus divided by one minus squared Poisson ratio. E’=E/(1-2) It is almost the same as Young modulus, and it is about twice as much as the shear modulus, because the Poisson ratio has little effect on it. For hard rock it might be 106 psi, for soft rock 105 psi or less. HF2D Page 4 Slurry injection rate (two wings, liq+ prop), bpm The injection rate is considered constant. It includes both the fracturing fluid and the proppant. The more proppant is added, the less the calculated liquid injection rate will be. A typical value is 30 bpm. Rheology, K' (lbf/ft^2)*s^n' Power law consistency of the fracturing fluid (slurry, in fact) Rheology, n' Power law flow behavior index Leakoff coefficient in pay layer, ft/min0.5 In general, the leakoff coefficient outside the pay layer may be less, than in the pay. Hence a multiplier is used outside the pay, see below. Spurt loss coefficient, Sp, gal/ft2 The spurt loss in the pay layer. Outside the permeable layer the spurt loss for out of pay is considered zero. See the remark above. Fluid loss multiplier for out of pay layer If this multiplier is set zero, there is no leakoff and spurt loss outside the pay layer. It is more realistic to use a multiplier between zero and one, say 0.5. Max possible added proppant concentration, The most important equipment constraint. Some current mixers can provide lbm/gallon fluid (ppga) more than 15 lbm/gal neat fluid. Often it is not necessary to go up to the maximum technically possible concentration. Multiply opt length by factor This design parameter can be used for sub-optimal design. If the optimum length is too small (and the fracture width is too large), a value greater than the one used. If the optimum length is too large (and the fracture width is too small) , a fractional value might be useful. This possibility of user intervention is advantageous to investigate the pros and contras of departing from the technical optimum. The default value should be 1. See more on this issue in the text. Multiply pad by factor In accordance with Nolte's suggestion, the exponent of the proppant concentration schedule and the pad fraction (relative to the total injected volume) are taken to be equal. This happens if this design parameter is at its default value, which is at 1. The user may experiment with other values. It will have the effect of shortening or elongating the pad period that is having less or more conservative design. The program adjusts the proppant schedule accordingly, to ensure the required amount of proppant is injected. HF2D Page 5 Additional input parameters TSO criterion Wdry/Wwet This design parameter appears only for TSO design. It specifies the ratio of dry width (assuming only the "dry" proppant is left in the fracture) to wet width (dynamically achieved during pumping). According to our assumptions, the screen-out happens when the ratio of dry to wet width reaches the user specified value. We suggest a number between 0.5 and 0.75., but the best method is gradually calibrate this parameter in the field by evaluating successful TSO treatments. HF2D Page 6 3 CALCULATED RESULTS The results contain the optimum fracture dimensions, followed by the fracture dimensions achieved taking into account the constraints (max possible added proppant concentration.) The constraints may or may not allow to achieve the technical optimum fracture dimensions. A red message will tell whether the optimum dimensions could be achieved. The main fracture dimensions, such as half-length, average width, areal proppant concentration determine the performance of the fractured well, which is given in terms of dimensionless productivity index and also as pseudo-skin factor. The fluid and proppant requirements are given in cumulative terms and the injection rate of the fluid and the added proppant concentration are presented as functions of time. HF2D Page 7 The results include: t, min time elapsed from start of pumping qi_liq, bpm liquid injection rate (for two wings) cum liq, gal cumulative liquid injected up to time t cadd, lbm/gal added proppant to one gallon of liquid, in other words ppga cum prop, lbm cumulative proppant injected up to time t xf, ft half-length of the fracture at time t wave, in. average width of the fracture at time t wave / Dpmx the ratio of average width of the fracture to the maximum proppant diameter, should be at least 3 wdry / wwet the ratio of dry to wet width. During pumping the actual wet width is 2 to 10 times larger than the dry width, that would be necessary to contain the same amount of proppant without any fluid and packed densely. Usually it should be less than a prescribed number, such as 0.2 for avoiding screen-out during the job. The TSO criterion in the TSO version of the design spreadsheet is formulated in terms of this output variable. HF2D Page 8 4 THEORETICAL FRACTURE PERFORMANCE The fracture design should be based on sound principles of fluid flow in porous media. We start the description of the fractured well performance with the pseudo-steady state Productivity Index. It is well understood that in tight gas the transient regime might last for a considerable time therefore well production is affected by the transient process. Nevertheless, it is impossible to understand the well behavior without first considering the pseudo-state flow regime. We consider a fully penetrating vertical fracture in a pay layer of thickness h, see Fig. 1 for notation. 2xf 2xf h w w xe 2re Fig. 1. Notation for fracture performance Note that in reality the drainage area is neither circular nor rectangular. Using re or xe is only a matter of convenience. The relation between re and xf is given by A re2 xe2 ................................................................... (1) HF2D Page 9 where A is the drainage area. Productivity Index The pseudo-steady state productivity index relates production rate to pressure drawdown: J q 2kh J D ........................................................... (2) p pwf 1 B where JD is called the dimensionless productivity index, k is the formation permeability, h is the pay thickness, B is the formation volume factor, is the fluid viscosity and 1 is a conversion constant (one for a coherent system). For a well located in the center of a circular drainage area the dimensionless productivity index reduces to JD 1 r 3 ln e s rw 4 .............................................................. (3) In the case of a propped fracture there are several ways to incorporate the stimulation effect into the productivity index. One can use the pseudo-skin concept: JD 1 ............................................................. (4) re 3 ln s f rw 4 or the equivalent wellbore radius concept: JD 1 r 3 ln e r'w 4 ................................................................ (5) or one can just provide the dimensionless productivity index as a function of the fracture parameters: JD = function(drainage-volume geometry, fracture parameters ) HF2D Page 10 All three options give exactly the same results (if done coherently). The last option is the most general and convenient, especially if we wish to consider fractured wells in a rectangular drainage area. Many authors have provided charts and correlations in one or another form for special geometries, reservoir types, etc. Unfortunately, most of the results are less obvious to apply in high permeability environment. Also there are quite large discrepancies as shown for instance on Fig. 12-13 of Reservoir Stimulation 3rd edition, 2000. Therefore we provide a fresh look at the partly known results. Proppant Number For a vertical well intersecting a rectangular vertical fracture which penetrates fully from the bottom to the top of the rectangular drainage volume the performance is known to depend on the x-directional penetration ratio: Ix 2x f xe ...................................................................... (6) and on the dimensionless fracture conductivity: C fD kf w kx f .................................................................... (7) where xf is the fracture half length, xe is the side length of the square drainage area, k is the formation permeability, kf is the proppant pack permeability, and w is the average fracture width. The key to formulating a meaningful technical optimization problem is to realize that penetration and dimensionless fracture conductivity (through width) are competing for the same resource: the propped volume. Once the reservoir and proppant properties and the amount of proppant are fixed, one has to make the optimal compromise between width and length. The available propped volume puts a constraint on the two dimensionless numbers. To handle the constraint easily we introduce the dimensionless proppant number: N prop I x2 C fD HF2D 4k f x f w kxe2 const ................................................. (8) Page 11 Note that only that part of the proppant counts into the propped volume, that reaches the pay. If for instance the fracture height is three times the net pay thickness, then the V prop can be calculated as the bulk volume of one third of the injected proppant, if it is closely packed. The Dimensionless Proppant Number, Nprop, is nothing else but the ratio of two volumes: the propped volume in the pay divided by the reservoir volume in the pay, both volumes weighted by their permeability, respectively. (In addition, a factor of two is used in front of the propped volume.) As we will see, the proppant number is the most important parameter in fracture design. A convenient algorithm to calculate JD is available1. Fig. 2 shows JD represented in a traditional manner, as a function of dimensionless fracture conductivity, CfD, with Ix as a parameter. Similar “productivity increase” graphs are numerous in the published literature2,3. 1 Valkó, P. P. and Economides,M.J.: “Heavy Crude Production from Shallow Formations: Long Horizontal Wells Versus Horizontal Fractures,” paper SPE 50421, 1998. 2 McGuire, W.J. and Sikora, V.J.: “The Effect of Vertical Fractures on Well Productivity,” Trans. AIME (1960) 219, 401-405. 3 Soliman, M.Y.: “Modifications to Production Increase Calculations for a Hydraulically Fractured Well,” JPT (Jan. 1983) 170-178. HF2D Page 12 Dimensionless Productivity index, JD 2 Ix = 1 0.9 0.8 ye = xe 1.5 2xf 0.7 0.6 xe 0.5 1 0.4 0.3 0.2 0.5 0.1 0.01 0 0.01 0.1 1 10 100 1000 Dimensionless Fracture Conductivity, CfD 10000 Fig. 2. Calculated dimensionless productivity index as a function of dimensionless fracture conductivity and penetration Fig. 2 is not very helpful to solve the optimization problem involving any fixed amount of proppant. For this purpose in Figs 3 and 4 we present the same results, but the individual curves correspond to JD at a fixed value of the proppant number, Nprop. Fig 3 a and Fig. 3 b emphasize the importance of the proppant number. HF2D Page 13 0.5 Dimensionless Productivity Index, JD Xe=Ye Ye Ix=1 2Xf 0.4 Np=0.1 Xe Np=0.06 Np=0.03 0.3 Np=0.01 Np=0.006 Np=0.003 Np=0.001 0.2 Np=0.0006 Np=0.0003 Np=0.0001 -4 -3 10 -2 10 -1 0 1 10 10 10 Dimensionless Fracture Conductivity, CfD 10 2 10 Fig. 3a. Dimensionless productivity index as a function of dimensionless fracture conductivity and proppant number (for Nprop < 0.1) 2.0 Dimensionless Productivity Index, JD Xe=Ye Ye Ix=1 2Xf Np=100 1.5 Np=60 Xe Np=30 Np=10 Np=6 1.0 Np=3 Np=1 Np=0.6 Np=0.3 0.5 Np=0.1 0.1 1 10 100 1000 Dimensionless Fracture Conductivity, CfD Fig. 3b. Dimensionless productivity index as a function of dimensionless fracture conductivity and proppant number (for Nprop > 0.1) HF2D Page 14 0.45 Dimensionless Productivity Index, JD Xe=Ye Ye 0.40 Np=0.1 2Xf Np=0.06 0.35 Xe Np=0.03 0.30 Np=0.01 Np=0.006 0.25 Np=0.003 0.20 Np=0.001 Np=0.0006 Np=0.0003 0.15 Np=0.0001 -1 -2 -3 10 10 Penetration Rate, IX 10 0 10 Fig. 4.a Dimensionless productivity index as a function of penetration ratio and proppant number (for Nprop < 0.1) Np=100 Dimensionless Productivity Index, DJ 1.8 1.6 Np=30 Xe=Ye Ye Np=10 2Xf Np=6 1.4 1.2 Xe Np=3 1.0 0.8 Np=1 Np=0.6 0.6 Np=0.3 0.4 Np=0.1 0.01 0.1 1 Penetration Rate, I X Fig. 4.b Dimensionless productivity index as a function of penetration ratio and proppant number (for Nprop > 0.1) HF2D Page 15 As seen from Figs. 3 a and b, for a given value of Nprop , that is for a fixed amount of available proppant, there exists an optimal dimensionless fracture conductivity, representing the optimal compromise between the ability of the fracture to conduct the flow into the wellbore and its ability to get inflow from the formation. Figs. 4 a and 4 b show the performance as a function of penetration ratio. The large JD values (above JD = 0.8) correspond to streamlines parallel to the y axis in pseudo-steady state, a highly desirable, but extremely difficult (if not impossible) to achieve situation. It is important to understand that Figs 3 a and 4 a are equivalent, and their correct use should lead to the same results. Similarly, Figures 3 b and 4 b carry equivalent information. One of the main result seen from the figures is, that at "low" proppant numbers (low proppant volume and/or high formation permeability), the optimal compromise occurs at CfD = 1.6. The behavior at large Nprop is as anticipated because we know that the absolute maximum for JD is 6/ = 1.909 (this value is the productivity index for a perfect linear flow in a square reservoir. When the propped volume increases, the optimal compromise happens at larger dimensionless fracture conductivities because the penetration cannot exceed unity. Figure 2.b shows this effect clearly. In “medium and high” permeability formations, that is above 50 md, it is practically impossible to achieve a proppant number larger than 0.1. For Frac-and Pack typical proppant numbers range between 0.0001 and 0.01 . Therefore, for medium/high permeability formations the optimum dimensionless fracture conductivity is always CfDopt = 1.6. In “tight gas” it is possible to achieve large dimensionless proppant numbers, at least in principle. If one calculates the proppant number with a limited drainage area and does not question whether the proppant really reached the pay layer, dimensionless proppant number 1 or even 5 can be calculated. However, the personal belief of this author is that proppant numbers larger than one are impossible to realize. The reason is that for large treatments there is a great uncertainty of where the proppant goes both in horizontal and in vertical direction. One has to be very optimistic to believe that the proppant injected remains in the pay layer vertically and also remains contained in the lateral direction with respect to the targeted drainage area. HF2D Page 16 For large treatments the drainage area is oftentimes dynamic in the sense that the extreme fracture length causes increase of the drainage area with respect to the originally targeted or even with respect to the existing well spacing. This author’s opinion is that a dimensionless proppant number larger than 0.5 is rarely realized, because the proppant can not be contained in the pay and within the drainage area. Unfortunately, in case of regular well-spacing the proppant extending laterally outside the drainage area can be totally discounted. It does not contribute to the proppant number and to the performance. The situation is more complex in case of an individual well in a larger area. Then the large fracture length tends to increase the drainage area and hence the proppant number decreases. Ultimately, the large fracture is beneficial, but the approximate upper limit (0.5) on the realizable proppant number still remains valid. The maximum possible dimensionless Productivity Index for Nprop = 0.5 is JD = 0.75 . The dimensionless Productivity Index of an undamaged vertical well is between 0.12 and 0.14 depending on the well spacing and assumed well radius. Therefore, there is a realistic maximum for the “ folds of increase” of the pseudo-steady state productivity (with respect to the zero skin case) and it is given by 0.75 / 0.13 ~ 6 . Any hope to achieve larger folds of increase (raised mostly by the simplicistic view: “equivalent wellbore radius equals xf/2”) ultimately has to face reality. Of course, much larger folds of increase can be achieved with respect to an originally damaged well (where the pre treatment skin factor is positive.) Another common misunderstanding is connected with the existence of the transient regime. In transient regime the Productivity Index (and hence the production rate) is larger than in pseudo-steady state. With this qualitative picture in mind it is easy to discard the pseudo-steady state optimization procedure and to “shoot” for very high dimensionless fracture conductivity and/or to anticipate much more folds of increase in the transient period. In reality, the existence of the transient period does not change the previous conclusions on optimal dimensions and should not induce too high anticipations. Our calculations show, that there is no reason to depart from the optimum compromise described above, even if the well will produce in transient regime for a considerable time (several months or even years.) HF2D Page 17 5 SUGGESTED DESIGN PROCEDURE BASED ON OPTIMAL PSEUDO-STEADY STATE PERFORMANCE To exploit the potentials of a given proppant number one has to place the proppant optimally (or near optimally). Therefore, the optimal design of a fracture treatment consists of two steps. The first one is to make a decision on size (in fact on proppant number). The second one is to design the treatment in such a way that we make maximum use of the potential of the realized proppant number. These issues are discussed in the following section. Sizing Specify the goal of the treatment in form of amount of proppant reaching the target layer. (Denote it by Vprop = 2Vf ). Calculate the proppant number, from that the maximum possible pseudo-steady state Productivity Index can already be computed. The target proppant number has to be at least 0.0001, otherwise there is no stimulation effect. It seems reasonable to select Nprop= 0.0005 - 0.001 as a target for many high permeability formations, because that would provide a JD about 0.2. Since wells in high permeability formations are often damaged (the pretreatment skin is a large positive number) most of the economic benefit comes from bypassing the original damage. To increase the JD significantly beyond 0.2, one would need order of magnitude larger proppant numbers, that is economically (and sometimes even technically) not feasible. It is the experience of this author that for tight gas it seems reasonable to select a target proppant number in the range between Nprop = 0.1 to 0.5 or sometimes around 1. The majority of formations are, however, not tight and neither of extreme high permeability. For those “medium” reservoirs the Nprop = 0.1 seems to be a reasonable target. HF2D Page 18 Of course, the above suggestions should be taken only as starting point. The actual sizing process should consider a whole range of proppant numbers including and evaluate the options by Net Present Value analysis. The most important thing to remember about the proppant number is that it has to be calculated with the proppant placed into the pay layer and with the representative in-situ conductivity of the proppant pack. The first problem requires the understanding of the layered structure of the reservoir and of the stress situation controlling fracture height containment (if any). In this respect, fracture propagation (3D or P3D modeling) plays an important role, but one has to be aware how the fracture dimensions will affect the final performance, and oftentimes in reality, this effect is less than that the literature and common belief suggest. The reason is that once the amount of proppant reaching the pay is already fixed, the actual fracture shape (especially the length) has limited effect on the final performance. To put it in simple words: the real question is not “what the length would be” but rather how much proppant would be placed into the target layer”. One of the most important concepts of the design procedure is the percentage of proppant reaching the target layer(s). If, for instance, several shale layers are imbedded between the pay layers, the actual proppant reaching the target might be less than 50 %, even with perfect height containment! The other important issue is the actual proppant pack permeability. The proppant number (and dimensionless fracture conductivity) have to be calculated with the in-situ representative permeability of the proppant pack. For instance, a proppant manufacturer may report 500 Darcy or even 1000 Darcy nominal permeability of the proppant at the estimated closure stress. In reality, however, because of the residue from the fluid, the actual retained permeability can be, for instance, 10 times less. If two phase flow is involved (gas with significant water, for instance) an other effect will dramatically decrease the effective (or apparent) permeability of the propped fracture. That effect is often referred to as non-Darcy flow. In the two-phase flow situation the origin of the additional energy loss in the fracture is due to the periodic acceleration and deceleration of the liquid droplets. This effect may be detrimental and may call for an additional factor of 5 or 10 to obtain a representative apparent permeability of the proppant pack. The understanding of the in-situ proppant permeability (conductivity) is therefore another important issue in fracture design. There is a large amount of information available on the actual in-situ conductivity of the proppant packs and it should be of primary concern of every design. Any other factor (such as vertical stress profile and variation of the Poisson ratio, dilatancy and/or apparent fracture toughness, wall building and/or radial leakoff, shear thickening and/or viscoelasticity, just to mention a few) should be consid- HF2D Page 19 ered after the sizing has been done correctly, taking into account the main issues such as: net pay thickness, formation permeability, percentage of proppant reaching the pay, apparent proppant permeability. In the sizing phase of the fracture design we make a decision on the dimensionless proppant number to realize. This determines the maximum possible Productivity Index and the optimum fracture dimensions are those realizing this “best” performance. Optimum fracture dimensions The optimum design represents the best compromise between width and length. Once we know the volume of the propped one-wing in the pay layer, Vf (note that this is half of the propped volume in the pay layer : Vf = Vprop /2 and, naturally, much less than half of the proppant volume injected) then we can use the definition of dimensionless fracture conductivity to obtain the optimum width and length: Vf k f xf C hk fDopt 1/ 2 C fDoptV f k w hk f ............................................................... (9) 1/ 2 ............................................................ (10) Once we know the proppant number, the optimum dimensionless fracture conductivity can be read from Fig. 3 a or b or calculated from suitable correlations built into the HF2D spreadsheet. Most often the optimum CfD will be 1.6, but the program can do the optimization for very large proppant numbers as well, where the optimum dimensionless fracture conductivity will be largergher. The fracture dimensions obtained from Eqs. 9 and 10 will realize the previously determined maximum possible Productivity Index. Of course, the above half-length and width are meant as “equivalent length” and “equivalent average propped width”, because the performance model represents the vertical fracture by a crude approximation as a rectangular fracture with constant width. HF2D Page 20 The actual shape of the fracture might be different but that can bring only minor deviations from the results presented here. (The most difficult thing in petroleum engineering is the separation of the really important effects from the lots parameters of secondary importance. ) Pumping Schedule Once the target length and width is known, one can proceed with the actual design of the treatment. The design includes the determination of the injection time, the necessary maximum added proppant concentration and the detailed proppant schedule realizing the optimum dimensions. The basic algorithm is described in the Appendix. If technical constraints do not allow the realization of the “optimum placement”, one has to make a departure from it, but only to the extent it is really necessary. For instance, in very low permeability formations the optimum width might be less than two or three proppant diameters. Then we have to put a constraint on the minimum width and modify the target width and length accordingly (still providing the target proppant number.) It can be shown with the presented curves that such a departure – if done only to the necessary extent - causes a loss of productivity that is within reasonable limits and most often not important at all. It is important to note that: o There is no theoretical difference between low and high permeability fracturing. In both cases there exists a technically optimal fracture, and in both cases it should have a dimensionless fracture conductivity depending solely on the proppant number. While in a low permeability formation this requirement results in a long and narrow fracture, in high permeability formations, a short and wide fracture will provide the same dimensionless conductivity. o Increasing the volume of proppant or the permeability of the proppant pack by a given factor (for example, 2 ) has exactly the same effect on the productivity if otherwise the proppant is placed optimally. HF2D Page 21 o To achieve the same post-treatment skin factor in a low and a high permeability formation the volume of proppant placed to the pay layer should be increased by the ratio of the formation permeabilities, provided all the other formation and proppant parameters are the same. o Since not all proppant will be placed into the permeable layer, the optimum length and width should be calculated with the effective volume, subtracting the proppant placed in the nonproductive layers. o In high permeability formations, the indicated fracture length might not be enough to bypass the damaged zone, therefore a minimum length should be applied. o Considerable fracture width can be lost because of proppant embedment into soft formations. For gas wells, non-Darcy effects may create a dependence of the apparent permeability of the proppant pack on the production rate itself. These issues are best handled by using proper effective width and effective peremeabilities in the conductivity expression (both in the proppant number and in the dimensionless proppant conductivity). Of course it is possible that the technical constraints (first of all maximum possible proppant concentration in the slurry) does not allow optimal placement. In case of conflict the design engineer has several options: e.g. choosing another type of fluid and/or equipment, but for higher permeability formations most likely a tip screenout (TSO) design has to be considered. The TSO design differs from the above procedure in one basic feature: it uses a TSO criterion to separate the lateral fracture propagation period from the width inflation period. In our design model this criterion is based on “dry to wet” average width ratio. The “TSO criterion” specifies the ratio of dry width (assuming only the "dry" proppant is left in the fracture) to wet width (dynamically achieved during pumping). According to our assumptions, the screen-out happens and fracture propagation stops when the ratio of dry to wet width reaches the user specified critical value. After the TSO is triggered, only the width is inflated, as far as additional slurry is injected. It is possible to schedule the proppant to such that the critical dry to wet width ratio is reached at that moment when the fracture length arrived at the desired distance. With TSO design, practically any width can be achieved, at least in principle. We suggest a number between 0.5 and 0.75. for the “TSO criterion: dry/wet width” parameter, but there is no good theoretical model behind this suggestion. (Unfortunately, if the formation does not allow it, it might be impossible to arrest fracture propagation (the rock is not soft enough, the elasticity modulus is too high, the leakoff is too high, etc.) There is no HF2D Page 22 clear procedure to predict if a TSO-type width inflation will be possible in the given formation or not. Engineering intuition and previous experience are of crucial importance in making that judgment.) Note that we use the word “optimum” for placing a given amount of proppant the best possible way into the formation. The determination of the optimum amount of proppant is called sizing. For optimum sizing one needs to know the costs and revenues. The costs increase with proppant number in a well defined manner. The revenues also increase with proppant number, and that can be calculated knowing the targeted Productivity Index. There is no need to do a detailed fracture design in order to size a treatment. (In fact sizing and detailed design should be separated. Optimum sizing should be done exclusively by the operator and not by the service company.) In case of conflict the design engineer may consider using another type of fluid and/or consider using equipment providing a higher maximum proppant concentration, and/or tip screenout design. There are several other checks the design engineer has to conduct. For instance, at the end of the pad injection the current hydraulic width should be large enough to accommodate proppant that is wet width per dry width should be at least 3. The TSO design differs from the above procedure in one basic feature: it uses the TSO criterion (critical ratio of wet width per dry width) to separate the lateral fracture propagation period from the width inflation period. It is possible that the design does not require a tip screenout. This is indicated by a message and then the user is suggested to run a traditional design without TSO. If the constraints do not allow the best placement of the proppant, the traditional PKN algorithms still provides a design, but the created fracture will be suboptimal. Warning messages indicate suboptimality and possible modification of injected proppant. In modifying the requirements the program takes the easy road, that is it reduces the amount of proppant placed. Sometimes this is acceptable, but more often you should explore other options. The first thing to look at is to use various fluids (that is changing rheology and leakoff), changing the injection rate or assuring larger maximum possible added proppant concentration by selecting a better equipment. HF2D Page 23 Often the optimum proppant placement can be realized by a tip-screenout design, and in such case the user should use the PKN-TSO method. The TSO design is not a well established procedure, because the prediction of the tip screen-out point is not based on sound physical principles. In our model a TSO criterion is used to trigger TSO and this criterion has to be selected carefully. That design parameter is only for TSO design. It specifies the ratio of dry width (assuming only the "dry" proppant is left in the fracture) to wet width (dynamically achieved during pumping). According to our assumptions, the screenout happens when the ratio of dry to wet width reaches the user specified value. We suggest a number between 0.5 and 0.75., but there is no good theoretical model behind this suggestion. Unfortunately, TSO treatment can be impossible, if the formation does not allow it (the rock is not soft enough, the leakoff is too high, etc.) There is no clear procedure to predict if a frac&pack type width inflation will be possible in the given formation or not. Engineering intuition and previous experience are of crucial importance in such case. If the given amount of proppant can not be placed optimally by a traditional design and you can not apply a TSO design (because the high leakoff, and/or high elastic modulus, and/or consolidated rock make it impossible) the traditional PKN design procedure should be used with an additional design factor that becomes especially important. In the spreadsheet it is called “multiply opt length by a factor”. Once you see the error message “Optimum placement of proppant is not possible” and you have tried all other options you have to make a decision on which design goal to relax. If you still want to place the originally specified amount of proppant, you have to depart from the optimum length. In such case you specify a factor of 2, 3, or even 10 to multiply the theoretically optimum length. With large enough factor used, you will be able to place all the proppant into the formation. The resulting suboptimal design will yield a reduced PI (compared to the optimum one.) At this point you have to decide whether it was a good idea to stick with the original amount of proppant. (It is possible that the answer is NO. As you will find, often a fraction of the original amount of proppant, BUT PLACED OPTIMALLY, gives almost the same PI as the large SUBOPTIMAL treatment while the cost of a small treatment is, of course, considerably less.) HF2D Page 24 6 HF2D SAMPLE RUNS Page 25 1) Traditional PKN design Input Proppant mass for (two wings), lbm 150,000 Sp grav of proppant material (water=1) 2.65 Porosity of proppant material 0.38 Proppant pack permeability, md 60,000 Max prop diameter, Dpmax, inch 0.031 Formation permeability, md 0.5 Permeable (leakoff) thickness, ft 45 Well Radius, ft 0.30 Well drainage radius, ft 2100 Pre-treatment skin factor 0.0 Fracture height, ft 120 Plane strain modulus, E' (psi) 2.00E+6 Slurry injection rate (two wings, liq+ prop), bpm 20 Rheology, K' (lbf/ft^2)*s^n' 0.0180 Rheology, n' 0.65 Leakoff coefficient in permeable layer, ft/min^0.5 0.00400 Spurt loss coefficient, Sp, gal/ft^2 0.01000 Fluid loss multiplier outside the pay 0 Max possible added proppant concentration, lbm/gal neat fluid 12 Multiply opt length by factor 1 Multiply Nolte pad by factor 1 HF2D Page 26 Part of Output Optimum placement without constraints Proppant number, Nprop 0.211 Dimensionless PI, JDopt 0.56 Optimal dimensionless fracture cond, CfDopt 1.7 Optimal half length, xfopt, ft 661.1 Optimal propped width, wopt, inch 0.1 Post treatment pseudo skin factor, sf -6.33 Folds of increase of PI 4.57 Constraints allow optimum placement Actual placement Proppant mass placed (2 wing) 150,000 Proppant number, Nprop 0.2111 Dimensionless PI, JDact 0.56 Dimensionless fracture cond, CfD 1.7 Half length, xf, ft 661.1 Propped width, w, inch 0.11 Post treatment pseudo skin factor, sf -6.33 Folds of increase of PI 4.57 HF2D Page 27 Treatment details Efficiency, eta, % 33.1 Pumping time, te, min 84.5 Pad pumping time, te, min 42.5 Exponent of added proppant concentration, eps 0.5029 Uniform proppant concentration in frac at end, lbm/ft^3 47.8 Areal proppant concentration after closure, lbm/ft^2 0.9 Max added proppant concentration, lb per gal clean fluid 9.0 Net pressure at end of pumping, psi 262.5 HF2D Page 28 2) PKN-TSO design Input Proppant mass for (two wings), lbm 50,000 Sp grav of proppant material (water=1) 2.65 Porosity of proppant material 0.38 Proppant pack permeability, md 60,000 Max propp diameter, Dpmax, inch 0.031 Formation permeability, md 15 Permeable (leakoff) thickness, ft 45 Well Radius, ft 0.30 Well drainage radius, ft 2,100 Pre-treatment skin factor 0.0 Fracture height, ft 75.0 Plane strain modulus, E' (psi) 2.00E+05 Slurry injection rate (two wings, liq+ prop), bpm 15.0 Rheology, K' (lbf/ft^2)*s^n' 0.0180 Rheology, n' 0.45 Leakoff coefficient in permeable layer, ft/min^0.5 0.00600 Spurt loss coefficient, Sp, gal/ft^2 0.02000 Fluid loss multiplier outside the pay 0 Max possible added proppant concentration, lbm/gallon fluid 16 Multiply opt length by factor 1 TSO criterion Wwet/Wdry 0.7 Multiply pad by factor 1 HF2D Page 29 Part of Output Optimum placement without constraints Proppant number, Nprop 0.0038 Dimensionless PI, JDopt 0.26 Optimal dimensionless fracture cond, CfDopt 1.6 Optimal half length, xfopt, ft 89.1 Optimal propped width, wopt, inch 0.4 Post treatment pseudo skin factor, sf -4.32 Folds of increase of PI 2.14 Optimum placement HF2D Page 30 TSO criterion was achieved Actual placement Proppant mass placed (2 wing) 50,000 Proppant number, Nprop 0.0038 Dimensionless PI, JDact 0.2644 Dimensionless fracture cond, CfD 1.64 Half length, xf, ft 89.1 Propped width, w, inch 0.4375 Post treatment pseudo skin factor, sf -4.32 Folds of increase of PI 2.14 Treatment details Pad pumping time, min 0.37 TSO time, min 7.1 Total pumping time, min 16.2 Mass of proppant in frac at TSO, lbm 13,628 Added proppant concentration at TSO, ca, lbm/gal liq 4.0 Half length at TSO, xf, ft 89.1 Average width at TSO, inch 0.6 Net pressure at TSO, psi 30.1 Max added proppant concentration at end, lbm/gal-liq 16.0 Areal proppant concentration after closure, lbm/ft^2 1.7 Net pressure at end of pumping, psi 79 HF2D Page 31 HF2D Page 32 NOMENCLATURE Bo = oil formation volume factor, RB/STB CfD = dimensionless fracture conductivity CL = leakoff coefficient, ft/min1/2 h = pay thickness, ft hp = net pay thickness, permeable thickness, ft hf = fracture height, ft Ix = penetration ratio, calculated for a square drainage area J = productivity index, BOPD/psi JD = dimensionless productivity index E' = plain strain modulus, psi k = effective formation permeability, mD kf = effective proppant pack permeability, mD K' = Power law consistency index , lbf/(ft2-sec) n' = Power law flow behavior index Nprop = proppant number p = average reservoir pressure, psi pwf = flowing bottomhole pressure, psi q = oil flow rate, STB/D qi = fluid injection rate, bpm rp = permeable to total area ratio rw = wellbore radius, ft r'w = equivalent wellbore radius due to fracture, ft HF2D Page 33 Rf = created fracture radius, ft sf = pseudo skin factor due to fracture te = pumping time, min Vi = injected volume, ft3 Vp = propped volume of the two wing contained in the pay layer, ft3 Vr = drainage volume: net height by drainage area, ft3 xf = fracture half length, ft xe = size of study area in x-direction ye = size of study area in y-direction w = propped fracture width, ft 1 = conversion factor (for field units 887.22) = pad fraction = Nolte exponent p = proppant pack porosity, fraction = opening time distribution factor, dimensionless = formation fluid viscosity, cp = fluid (slurry) efficiency, fraction HF2D Page 34 A CASE STUDIES Table 1 Overview Medium Permeability Formation MPF Standard MPF01 Pushing the limit MPF02 Proppant Embedment MPF03 Non-Darcy Fracture face skin High Permeability Formation HPF Standard MPF01 Extreme High MPF02 Low Permeability Formation LPF HF2D Low Permeability (tight gas) LPF01 Page 35 A.1 A Typical Preliminary Design: Medium Permeability Formation, MPF01 In the remaining part of this chapter we will illustrate the design logic incorporated in the Unified Fracture Design. We will intentionally consider cases, where only limited data are available. Table 2 shows available data for a “medium” permeability formation (with permeability 1.7 md. and net pay of 76 ft). The input data contains the well radius and the drainage radius (calculated from 40 acre spacing). These important reservoir parameters should not be missed. A preliminary sizing decision is that 90,000 lbm proppant should be injected. At the closure stress anticipated (5000 psi) the selected resin coated 20/40 mesh sand will have an in-situ permeability of 60,000 md. In this number we already incorporated the effect of some proppant crushing and the decrease of proppant pack permeability due to imperfect breaking of the gel. Obviously, this is one of the key parameters of the design, and the design engineer has to do everything in her/his power to make this estimate as relevant as possible. (Buying an expensive 3D program with vendor provided proppant data and clicking the name of the proppant is obviously not enough.) The plane-strain modulus (that is basically the Young modulus) is 2106 psi. Minifrac tests in the same formation with the same fluid usually result in a leakoff coefficient 0.005 ft/min1/2 and some spurt loss is also anticipated. (Note that these values are with respect to the pay layer. It is assumed, that outside the pay there is no leakoff.) The fluid rheology parameters are provided by the service company and (because of pressure limitations in this case) the injection rate is 20 bpm. HF2D Page 36 Table 2. Input Data For MPF01 Proppant mass for (two wings), lbm 90,000 Sp grav of proppant material (water=1) 2.65 Porosity of proppant pack 0.38 Proppant pack permeability, md 60,000 Max propp diameter, Dpmax, inch 0.031 Formation permeability, md 1.7 Permeable (leakoff) thickness, ft 76 Well Radius, ft 0.25 Well drainage radius, ft 745 Pre-treatment skin factor 0.0 Fracture height, ft Plane strain modulus, E' (psi) 2.0E+06 Slurry injection rate (two wings, liq+ prop), bpm 20.0 Rheology, K' (lbf/ft2)sn' 0.07 Rheology, n' 0.45 Leakoff coefficient in permeable layer, ft/min1/2 0.005 Spurt loss coefficient, Sp, gal/ft^2 0.010 The input data are summarized in Table 2. The line of fracture height is still left empty. We know that the gross pay is 100 ft, that is the distance between the top and bottom perforations is 100 ft. Within this interval, only 76 ft is pay, though. A preliminary estimate of fracture height should be minimum 100 ft, but the actual height will be related to several other factors. HF2D Page 37 A reasonable assumption – in the absence of any reliable data on stress contrast – is, that the aspect ratio of the created fracture is 2:1 . In other words, we will find the fracture height, hf, by adjusting it to the target length, according to hf = xf . At this point we put a starting estimate of hf =100 ft into our design spreadsheet and we specify the following operational constraint/parameters, as shown in Table 3: Table 3. Additional Input For MPF01 Max possible added proppant concentration, lb m/gal neat fluid 12 Multiply opt length by factor 1 Multiply Nolte pad by factor 1 The maximum available proppant concentration in ppga (lbm proppant added to 1 gallon of neat fracturing fluid) is 12 according to the service company. The other two parameters are fixed at their default value. The output of the first run of our design spreadsheet contains three parts. In the first part a “wish-list” is shown. Table 4. Theoretical Optimum for MPF01-1 HF2D Page 38 Output Optimum placement without constraints Proppant number, Nprop 0.3552 Dimensionless PI, JDopt 0.65 Optimal dimensionless fracture cond, CfDopt 1.8 Optimal half length, xfopt, ft 294.2 Optimal propped width, wopt, inch 0.2 Post treatment pseudo skin factor, sf -5.72 Folds of increase of PI 4.74 It states that the proppant number is 0.35 and with the proppant placed optimally we could achieve a dimensionless productivity index of 0.65 that is a skin factor as negative as –5.72. The Folds of increase in productivity (with respect to the zero skin situation we fixed in line 10 of the input as the basis of comparison ) is 4.74 . A red warning message is, however, indicating, that our wish-list could not be realized: Suboptimal placement with constraints satisfied Mass of proppant reduced The actual placement, the design program was able to produce is somewhat disappointing, as shown in Table 5: HF2D Page 39 Table 5. Actual placement for MPF01-1 Actual placement Proppant mass placed (2 wing) 58,501 Proppant number, Nprop 0.2309 Dimensionless PI, JDact 0.57 Dimensionless fracture cond, CfD 1.2 Half length, xf, ft 294.2 Propped width, w, inch 0.12 Post treatment pseudo skin factor, sf -5.50 Folds of increase of PI 4.15 In other words, the design program can assure only the placement of 58,500 lbm proppant. The reason for this will be discussed later. At this point we should not pay too much attention to it, because our specified fracture height (100 ft) was not realistic. To approach our required aspect ratio: hf =xf we increase the fracture height to 200 ft. The calculated theoretical optimum target length is now hf = 216 ft. A third adjustment to hf =211 ft will finally establish the required aspect ratio. HF2D Page 40 Table 6. Theoretical Optimum for MPF01-3 ( hf = 211 ft ) Optimum placement without constraints Proppant number, Nprop 0.1684 Dimensionless PI, Jdopt 0.53 Optimal dimensionless fracture cond, CfDopt 1.6 Optimal half length, xfopt, ft 211.1 Optimal propped width, wopt, inch 0.1 Post treatment pseudo skin factor, sf -5.37 Folds of increase of PI 3.85 We see that the proppant number is significantly less: 0.168, than previously. Why did this happen? Because the increase in fracture height decreases the volumetric proppant efficiency, that is the part of proppant “working for us”. The optimum length corresponding to this proppant number is 211 ft, and that means that our fracture – if it can be realized – will have the desired 2:1 aspect ratio. But can it be realized? The red message: Constraints allow optimum placement shows that yes, the optimum placement can be realized. HF2D Page 41 Table 6. Actual Placement MPF01-3 ( hf = 211 ft ) Actual placement Proppant mass placed (2 wing) 90,000 Proppant number, Nprop 0.1684 Dimensionless PI, JDact 0.53 Dimensionless fracture cond, CfD 1.6 Half length, xf, ft 211.1 Propped width, w, inch 0.12 Post treatment pseudo skin factor, sf -5.37 Folds of increase of PI 3.85 We found that the 90,000 lbm proppant can be safely placed into the well. Not all of the proppant will be placed into the pay layer, though. The part of the proppant reaching the pay will represent a proppant number Nprop = 0.168, and the optimum half length corresponding to it is 211 ft. The treatment will establish a dimensionless productivity index, JDact = 0.53 in other words a negative equivalent skin, sf = -5.37 will be created. Note that the whole design logic is based on the proppant number concept. We do not specify an arbitrary length, rather we obtain the optimum length and the design process makes sure that the desired length is realized and the desired amount of proppant is placed uniformly. Some details of the treatment are shown in Table 7. HF2D Page 42 Table 7. Some Details of the Actual Placement MPF01-3 ( hf = 211 ft ) Treatment details Efficiency, eta, % 34.5 Pumping time, te, min 40.4 Pad pumping time, te, min 19.7 Exponent of added proppant concentration, eps 0.4871 Uniform proppant concentration in frac at end, lbm/ft^3 57.5 Areal proppant concentration after closure, lb m/ft2 1.0 Max added proppant concentration, lb per gal clean fluid 11.8 Net pressure at end of pumping, psi 132.5 More details can be found by running the spreadsheet. A.2 Pushing the limit: Medium Permeability Formation, MPF02 For illustrative purposes we will consider MPF01 as our base case. In this section we ask the question: can we place 150,000 lb proppant in a similar manner? If yes, what good will it do for the well productivity? The reader is now able to do the design so we will not show the detailed “iteration”, only the main results. HF2D Page 43 Table 8. Some Details of the Input MPF02-3 ( hf = 248 ft ) Proppant mass for (two wings), lbm 150,000 … Fracture height, ft 248 … Table 9. Theoretical optimum for MPF02-3 ( hf = 248 ft ) Output Optimum placement without constraints Proppant number, Nprop 0.2387 Dimensionless PI, JDopt 0.58 Optimal dimensionless fracture cond, CfDopt 1.7 Optimal half length, xfopt, ft 248.0 Optimal propped width, wopt, inch 0.1 Post treatment pseudo skin factor, sf -5.54 Folds of increase of PI 4.23 The first thing we should note that the increase of proppant and corresponding increase of proppant number will result – even if everything goes well – only a marginal improvement in productivity. This should make us think whether it is worth “pushing the limit”. Even more food for thought is provided by the message: Suboptimal placement with constraints satisfied Mass of proppant reduced and by the next output: HF2D Page 44 Table 10. Actual placement for MPF02-3 ( hf = 248 ft ) Actual placement Proppant mass placed (2 wing) 136,965 Proppant number, Nprop 0.2180 Dimensionless PI, JDact 0.57 Dimensionless fracture cond, CfD 1.5 Half length, xf, ft 248.0 Propped width, w, inch 0.13 Post treatment pseudo skin factor, sf -5.49 Folds of increase of PI 4.12 Treatment details Efficiency, eta, % 36.1 Pumping time, te, min 58.0 Pad pumping time, te, min 27.2 Exponent of added proppant concentration, eps 0.4694 Uniform proppant concentration in frac at end, lbm/ft^3 58.2 Areal proppant concentration after closure, lbm/ft^2 1.1 Max added proppant concentration, lb per gal clean fluid 12.0 Net pressure at end of pumping, psi 122.9 As we see the design program had to reduce the amount of proppant placed into the formation. With this reduction the actual folds of increase is hardly more than what we can achieve with 90,000 lb proppant and it is obvious that “pushing the limit” in this case is not worth the effort and money. But is it really obvious? Several service companies would rather suggest a better equipment capable to do as high proppant concentration as 16 ppga. HF2D Page 45 Table 11. Actual placement for MPF02-4 ( hf = 248 ft, max possible conc: 16 ppga ) Max possible added proppant concentration, lbm/gal neat fluid 16 The message is now encouraging: Constraints allow optimum placement Table 12. Actual placement for MPF02-3 ( hf = 248 ft, max possible conc: 16 ppga ) Actual placement Proppant mass placed (2 wing) 150,000 Proppant number, Nprop 0.2387 Dimensionless PI, JDact 0.58 Dimensionless fracture cond, CfD 1.7 Half length, xf, ft 248.0 Propped width, w, inch 0.14 Post treatment pseudo skin factor, sf -5.54 Folds of increase of PI 4.23 Treatment details Efficiency, eta, % 64.0 Pumping time, te, min 32.7 Pad pumping time, te, min 7.2 Exponent of added proppant concentration, eps 0.2191 Uniform proppant concentration in frac at end, lbm/ft^3 63.7 Areal proppant concentration after closure, lbm/ft^2 1.2 Max added proppant concentration, lb per gal clean fluid 13.9 Net pressure at end of pumping, psi 122.9 HF2D Page 46 The increase in the maximum possible proppant concentration did the trick. It is now possible to place the required quantity of proppant (because larger concentration allows to put more proppant into the same width). In fact we did not even use all the capabilities of the equipment, a 14 ppga maximum proppant concentration would be enough. Also it is clear that our actual design now realizes the “wish-list” originally stated in Table 9. The question, whether it is worth doing the larger treatment or not, is however, still open. Only careful economic calculations can tell if it is worth doing the larger treatment, that will be about 50 % more expensive, but will realize a post treatment skin of –5.54 instead of the –5.50 calculated for our base case, MPF01-3. Since the difference is clearly in the “error margin” it is difficult to believe that a manager would decide on the more expensive (and more risky) larger treatment. A.3 Proppant Embedment: MPF03 It is well-known, that in softer formations a considerable part of the injected proppant might be “lost” because it is embedded into the formation wall. Some estimates talk about 30 % loss of width because of embedment (Lacy, 1994) Let us assume that the rock mechanics lab measured a 33.3 % embedment for the given formation and closure stress. How can we incorporate this into the design? The easiest way is to say that the proppant pack permeability (now 60,000 md) will apparently be reduced to 40,000 md. Changing one input line of case MPF01-3, that is putting Proppant pack permeability, md HF2D 40,000 Page 47 Table 13. Theoretical Optimum for MPF03-3 ( hf = 185 ft ) Optimum placement without constraints Proppant number, Nprop 0.1280 Dimensionless PI, JDopt 0.50 Optimal dimensionless fracture cond, CfDopt 1.6 Optimal half length, xfopt, ft 185.2 Optimal propped width, wopt, inch 0.2 Post treatment pseudo skin factor, sf -5.23 Folds of increase of PI 3.60 As we see, now the maximum possible dimensionless productivity index is less, only 0.50, but even this can not be realized as the error message indicates: Suboptimal placement with constraints satisfied Mass of proppant reduced Table 13. Theoretical Optimum for MPF03-3 ( hf = 185 ft ) Actual placement Proppant mass placed (2 wing) 65,285 Proppant number, Nprop 0.0929 Dimensionless PI, JDact 0.46 Dimensionless fracture cond, CfD 1.2 Half length, xf, ft 185.2 Propped width, w, inch 0.11 Post treatment pseudo skin factor, sf -5.06 Folds of increase of PI 3.31 HF2D Page 48 In fact only 65,300 lb proppant can be placed because the width at 185 ft is less than it was at 211 ft and because we need more width to compensate for the loss of conductivity (due to embedment.) To make the design possible we will depart from the optimum by multiplying the theoretical optimum length by a factor. In this case we select the factor to target 250 ft for length, so we change the height to 250 ft (remember, we still use the 2:1 aspect ratio as most probable) and then we have to find a factor resulting in the half length 250 ft. This value is 1.58: Table 14. Height and Constraint for MPF03-4 Fracture height, ft 250 Max possible added proppant concentration, lbm/gal neat fluid 12 Multiply opt length by factor 1.58 Multiply Nolte pad by factor 1 Table 15. First Part of Output for MPF03-4 Output Optimum placement without constraints Proppant number, Nprop 0.0947 Dimensionless PI, JDopt 0.46 Optimal dimensionless fracture cond, CfDopt 1.6 Optimal half length, xfopt, ft 158.9 Optimal propped width, wopt, inch 0.1 Post treatment pseudo skin factor, sf -5.08 Folds of increase of PI 3.34 HF2D Page 49 The message shows that the sub-optimal placement with the required modification can be realized: Suboptimal placement with constraints satisfied Length modified Table 16. Additional Output for MPF03-4 Actual placement Proppant mass placed (2 wing) 90,000 Proppant number, Nprop 0.0947 Dimensionless PI, Jdact 0.44 Dimensionless fracture cond, CfD 0.7 Half length, xf, ft 251.0 Propped width, w, inch 0.08 Post treatment pseudo skin factor, sf -4.98 Folds of increase of PI 3.19 Now we can place all the 90,000 lb proppant but we have to depart from the theoretical optimum placement. The “success” is, however, questionable, because with all the 90,000 lb proppant placed we still create only a - 4.98 equivalent skin, while the 65,300 lb – placed according to MPF03-3 – actually creates a better skin: -5.06. By now the reader might feel why we call our approach “Unified Fracture Design”. The systematic use of the proppant number and the optimality criterion makes the decisions more transparent. A.4 Non-Darcy Flow in the fracture For high-rate gas wells, where a certain percentage liquid content of the gas is inevitable, the concept of proppant pack permeability deserves special attention. When the gas-liquid mixture flows in the propped HF2D Page 50 fracture with high velocity, the liquid droplets collide with the proppant grains and the result is a significant dissipation of energy (loss of pressure). As a result, the nominal permeability contrast (in the fracture vs in the formation) is not representative for the relative magnitude of pressure losses. The fracture behaves, as if its apparent permeability were much less, than the nominal value measured at single phase flow conditions. There is an extensive literature available describing this non-Darcy flow effect in the fracture (Jin and Penny, 2000, Cikes, M. 2000, Milton-Tayler, 1993, Gidley, 1990, Guppy et al., 1982). From our point of view it is enough to understand, that at actual flow conditions the proppant pack can be described by an apparent permeability – or if we wish – a correction factor multiplying the nominal permeability. Depending on the actual velocity of the gas, the liquid content and the droplet size distribution, in addition to the proppant quality, the correction factor can be as low as 0.1. The treatment of this phenomenon within the Unified Fracture Design is relatively simple. Using an estimate of the correction factor, the apparent proppant permeability should be reduced, for instance from 60,000 md to 10,000 md. From the calculated maximum productivity index – corresponding to the corrected proppant number – a better estimate of the anticipated gas velocity can be obtained. (For this calculation a drawdown has to be assumed and the properties of the gas – liquid mixture have to be known.) With the improved estimate of gas velocity, an improved estimate of the non-Darcy flow correction factor can be obtained and the design can be continued using the corrected proppant number. For instance, in our previous example the proppant number calculated with a nominal permeability: 60,000 md was obtained as Nprop = 0.095 . In the presence of significant non-Darcy effect, this number should be reduced to Nprop = 0.05 or – in extreme cases – to Nprop = 0.01. If we want to compensate for the loss of productivity, we have to increase the amount of proppant placed into the pay by the same factor. A.5 Compensating for fracture face skin In a certain reservoir it is suspected that the fracturing fluid filtrate will interact with the formation and an estimated fracture face skin sff = 1 will be created. What is the effect of this phenomenon on the productivity of the well and how can we compensate for it? Assume the proppant number of the suggested treatment is about Nprop = 0.1. We recall, that the maximum of the dimensionless productivity index that can be achieved with Nprop = 0.1 is (see Chapter 3): HF2D Page 51 J D max 1 0.47 0.99 0.5 ln N prop (8) If there is a fracture face skin sff = 1, (and we assume the simple case of uniform influx) then the actual productivity will be J D actual 1 0.32 0.99 0.5 ln N prop 1 (9) The fracture face skin causes a considerable decrease in productivity. From the equation it is seen that approximately e2 = 7.4 times more proppant would compensate for the loss of productivity caused by a fracture face skin of one. A.6 Fracture Design for High Permeability Formation: HPF01 In high permeability formations the optimality criterion will result in a short and wide fracture. To have a basis for comparison, we will use the previous data set except for the following variables: permeability, plane strain modulus, spurt loss and leakoff coefficient. HF2D Page 52 Table 17. Input Data For MPF01 Proppant mass for (two wings), lbm 90,000 Sp grav of proppant material (water=1) 2.65 Porosity of proppant pack 0.38 Proppant pack permeability, md 60,000 Max propp diameter, Dpmax, inch 0.031 Formation permeability, md 50 Permeable (leakoff) thickness, ft 76 Well Radius, ft 0.25 Well drainage radius, ft 745 Pre-treatment skin factor 0.0 Fracture height, ft Plane strain modulus, E' (psi) 7.5E+05 Slurry injection rate (two wings, liq+ prop), bpm 20.0 Rheology, K' (lbf/ft2)sn' 0.07 Rheology, n' 0.45 Leakoff coefficient in permeable layer, ft/min1/2 0.01 Spurt loss coefficient, Sp, gal/ft^2 0.02 The line of fracture height is still left empty. We know that the gross pay is 100 ft, that is the distance between the top and bottom perforations is 100 ft. A reasonable assumption for high permeability fracturing – in the absence of any reliable data on stress contrast – is, that extensive height growth will not occur as far as the target length is less than half of the height. At this point we put a starting estimate of hf =100 ft into our design spreadsheet and we specify the following operational constraint/parameters, as shown in Table 18: HF2D Page 53 Table 18. Additional Input For HPF01 Max possible added proppant concentration, lbm/gallon fluid 16 Multiply opt length by factor 1 Multiply pad by factor 1 Table 19. Theoretical optimum for HPF01-1 Optimum placement without constraints Proppant number, Nprop 0.0121 Dimensionless PI, Jdopt 0.31 Optimal dimensionless fracture cond, CfDopt 1.6 Optimal half length, xfopt, ft 56.7 Optimal propped width, wopt, inch 0.9 Post treatment pseudo skin factor, sf -4.05 Folds of increase of PI 2.27 From the first design attempt we see that the proppant number is Nprop = 0.012 . This is a typical situation for high permeability formations: not even a considerable amount of proppant and well contained fracture height will produce large proppant numbers. The message says that Suboptimal placement with constraints satisfied Mass of proppant reduced HF2D Page 54 Table 20. Actual placement without TSO design: HPF01-1 Actual placement Proppant mass placed (2 wing) 10,702 Proppant number, Nprop 0.0014 Dimensionless PI, JDact 0.21 Dimensionless fracture cond, CfD 0.2 Half length, xf, ft 56.7 Propped width, w, inch 0.11 Post treatment pseudo skin factor, sf -2.50 Folds of increase of PI 1.53 In fact only 10,700 lbm proppant can be placed into the formation, if the target length is 56.7 ft. Such a treatment would realize a very low proppant number and an equivalent skin of –2.5, that is usually not satisfactory, especially because other factors can decrease further the stimulation effect. The problem is, that the width of the fracture (even though this is a relatively “soft” formation) created during normal fracture propagation is not enough to accept more proppant. (Note that we have already increased the maximum possible proppant concentration to 16 ppga, but that is still not enough.) The solution to the problem is to design a TSO treatment. Knowing that the formation is “soft” and relatively unconsolidated, we intentionally arrest fracture propagation at the target length (56.7 ft) and inflate the fracture from there on. For the TSO design we use exactly the same input as previously, the only additional parameter is: TSO criterion Wdry/Wwet 0.7 The meaning of this parameter is, that we anticipate the fracture to stop propagating if – because of fluid loss, in other words dehydration – the “dry width” is already near to the “wet width”. The dry width is HF2D Page 55 defined as the width of the fracture after all fluid have leaked off, while the wet width is the width during the treatment when still part of the proppant carrying fluid has not leaked off. We use the critical value of 0.7, but depending on the actual fracture shape and proppant type the value might vary. Table 21. Actual placement with TSO design: HPF01-TSO Actual placement Proppant mass placed (2 wing) 90,000 Proppant number, Nprop 0.0121 Dimensionless PI, JDact 0.3127 Dimensionless fracture cond, CfD 1.64 Half length, xf, ft 56.7 Propped width, w, inch 0.9282 Post treatment pseudo skin factor, sf -4.05 Folds of increase of PI 2.27 From the output we see, that with TSO we could place all the proppant into the 57-ft long fracture. This is achieved by (internally) adjusting the proppant schedule to reach the critical proppant concentration in the fracture when the lateral extension reaches the target length. HF2D Page 56 Table 22. Actual placement with TSO design: HPF01-TSO Treatment details Pad pumping time, min 0.41 TSO time, min 7.9 Total pumping time, min 24.8 Mass of proppant in frac at TSO, lbm 11,065 Added proppant concentration at TSO, ca, lbm/gal liq 2.0 Half length at TSO, xf, ft 56.7 Average width at TSO, inch 1.2 Net pressure at TSO, psi 81.1 Max added proppant concentration at end, lbm/gal-liq 16.0 Areal proppant concentration after closure, lbm/ft^2 1.3 Net pressure at end of pumping, psi 482 In fact 11,000 lb proppant is placed into the fracture in a usual manner in less than 8 minutes. After that 18 16 14 12 10 8 6 4 2 0 20 15 10 5 0 0 5 10 15 20 25 30 600 Net pressure, psi 25 ca, lbm prop added to gallon liquid Liquid injection rate, bpm the fracture length remains constant and only the width inflated. 500 400 300 200 100 0 0 5 Pumping time, min 10 15 20 25 30 Pumping time, min Fig. 3 Fluid, proppant schedule and net pressure forecast for the TSO treatment. The net pressure is considerable, almost 500 psi at the end of the treatment. This is anticipated, because the optimum placement calls for an almost 1-inch propped fracture width. HF2D Page 57 A.7 Extreme High Permeability: HPF02 In naturally fractured formations several hundred md permeabilities are not uncommon. To investigate this territory we repeat the design with the same input, except for Formation permeability, md 500 Table 23. Theoretical optimum for: HPF02 Optimum placement without constraints Proppant number, Nprop 0.0012 Dimensionless PI, JDopt 0.23 Optimal dimensionless fracture cond, CfDopt 1.6 Optimal half length, xfopt, ft 17.9 Optimal propped width, wopt, inch 2.9 Post treatment pseudo skin factor, sf -2.90 Folds of increase of PI 1.67 As we see, the target length is now 18 ft. In fact the design program can produce a TSO design for this case also: HF2D Page 58 Table 24. First attempt for HPF02 Actual placement Proppant mass placed (2 wing) 90,000 Proppant number, Nprop 0.0012 Dimensionless PI, JDact 0.2299 Dimensionless fracture cond, CfD 1.64 Half length, xf, ft 17.9 Propped width, w, inch 2.9351 Post treatment pseudo skin factor, sf -2.90 Folds of increase of PI 1.67 but the design cannot be accepted, because it would result in an extremely high net pressure, as seen from Table 25. Table 25. First attempt for HPF02 Treatment details Pad pumping time, min 0.06 TSO time, min 1.2 Total pumping time, min 18.6 Mass of proppant in frac at TSO, lbm 2,353 Added proppant concentration at TSO, ca, lbm/gal liq 3.0 Half length at TSO, xf, ft 17.9 Average width at TSO, inch 5.4 Net pressure at TSO, psi 54.5 Max added proppant concentration at end, lbm/gal-liq 16.0 Areal proppant concentration after closure, lbm/ft^2 0.9 Net pressure at end of pumping, psi 2142 HF2D Page 59 Several parameters have unrealistic values in the results of the first attempt. The extremely short fracture – even if it could be realized – would not be necessarily useful, because the near wellbore damage might be still dominating at such distances. A reasonable design would call for longer fracture. From an operational point of view, net pressure limitation is the most important constraint in high permeability fracturing. A maximum allowable net pressure should be specified from safety considerations. A typical value would be for instance 1000 psi. Therefore we will modify our design in order to satisfy this limitation. We have several options. One possibility is to depart from the optimum length, that is multiplying it by a factor. A realistic design would try to keep the 1:1 aspect ratio, therefore we select Multiply opt length by factor 3 That would give us a placement Table 26. HPF02 with modified length Actual placement Proppant mass placed (2 wing) 90,000 Proppant number, Nprop 0.0012 Dimensionless PI, JDact 0.2058 Dimensionless fracture cond, CfD 0.18 Half length, xf, ft 53.8 Propped width, w, inch 0.9784 Post treatment pseudo skin factor, sf -2.39 Folds of increase of PI 1.49 HF2D Page 60 Treatment details Pad pumping time, min 0.38 TSO time, min 7.2 Total pumping time, min 24.2 Mass of proppant in frac at TSO, lbm 10,308 Added proppant concentration at TSO, ca, lbm/gal liq 2.1 Half length at TSO, xf, ft 53.8 Average width at TSO, inch 1.3 Net pressure at TSO, psi 79.7 Max added proppant concentration at end, lbm/gal-liq 16.0 Areal proppant concentration after closure, lbm/ft^2 1.3 Net pressure at end of pumping, psi 521 Such a treatment already satisfies the net pressure constraint. The calculated design calls for starting the addition of proppant almost from the beginning of the treatment. Unfortunately, the design depends heavily on the selected TSO criterion and on the accuracy of the leakoff description. In reality, it is difficult to predict the TSO with such an accuracy. The art of arresting fracture propagation but still avoiding a near-wellbore screenout (that would cause us to stop the treatment) often requires the intuition and experience of the fracturing engineer. The operator company may increase the chance for success by reducing the risks associated with the treatment. That leads us to another possibility: to reduce the amount of proppant and multiply the optimum length by a factor, at the same time: Proppant mass for (two wings), lbm 45,000 Multiply opt length by factor 4 HF2D Page 61 Table 27. HPF02 with less proppant and modified length Proppant number, Nprop 0.0006 Actual placement Proppant mass placed (2 wing) 45,000 Proppant number, Nprop 0.0006 Dimensionless PI, JDact 0.1847 Dimensionless fracture cond, CfD 0.10 Half length, xf, ft 50.7 Propped width, w, inch 0.5189 Post treatment pseudo skin factor, sf -1.84 Folds of increase of PI 1.34 Treatment details Pad pumping time, min 0.34 TSO time, min 6.5 Total pumping time, min 14.0 Mass of proppant in frac at TSO, lbm 9,523 Added proppant concentration at TSO, ca, lbm/gal liq 2.1 Half length at TSO, xf, ft 50.7 Average width at TSO, inch 0.6 Net pressure at TSO, psi 78.1 Max added proppant concentration at end, lbm/gal-liq 16.0 Areal proppant concentration after closure, lbm/ft^2 1.2 Net pressure at end of pumping, psi 239 HF2D Page 62 The important thing to note is, that there is little to lose when we reduce the proppant number from 0.0012 to 0.0006. In this proppant number region the dimensionless productivity index is less sensitive to the amount of proppant or to the departure from the optimum length, as a matter of fact. Only a moderately negative equivalent skin factor can be realized at such low proppant numbers. This explains the widely accepted view that in extremely high permeability formations the most important issue is “to get behind the damage” and create a pack (“halo”) around the screen. The actual fracture length has less significance. Many high permeability fracturing treatments use only 50,000 lbm or less proppant. A.8 Low Permeability Fracturing: LPF01 To maintain consistency with our previous examples we consider a low permeability formation with most of the input parameters similar to our base case: Table 28. Input for LPF01 Proppant mass for (two wings), lbm 90,000 Sp grav of proppant material (water=1) 2.65 Porosity of proppant pack 0.38 Proppant pack permeability, md 60,000 Max 0.031 rop diameter, Dpmax, inch Formation permeability, md 0.5 Permeable (leakoff) thickness, ft 76 Well Radius, ft 0.25 Well drainage radius, ft 745 Pre-treatment skin factor 0.0 HF2D Page 63 Fracture height, ft Plane strain modulus, E' (psi) 2.00E+06 Slurry injection rate (two wings, liq+ prop), bpm 20.0 Rheology, K' (lbf/ft^2)*s^n' 0.070 Rheology, n' 0.45 Leakoff coefficient in permeable layer, ft/min^0.5 0.0020 Spurt loss coefficient, Sp, gal/ft^2 0.0010 Max possible added proppant concentration, lbm/gal neat fluid 12 Multiply opt length by factor 1 Multiply Nolte pad by factor 1 Again we will start the design by specifying hf = 100 ft. Table 29. Theoretical optimum assuming 100 ft fracture height: LPF01 Optimum placement without constraints Proppant number, Nprop 1.2077 Dimensionless PI, JDopt 1.06 Optimal dimensionless fracture cond, CfDopt 2.9 Optimal half length, xfopt, ft 423.0 Optimal propped width, wopt, inch 0.1 Post treatment pseudo skin factor, sf -6.30 Folds of increase of PI 7.66 HF2D Page 64 The proppant number is large, because of the large contrast in permeabilities. At such large proppant number the indicated fracture half length is already near to the “side length” of the drainage area (this is why the optimum dimensionless fracture conductivity is significantly more than 1.6). If such a fracture could be realized, an extremely large dimensionless productivity index would be established. Unfortunately, there is little chance that a fracture with aspect ratio 8:1 could be created without height increase. It is more likely that an aspect ratio of about 2:1 will be obtained. Therefore we base our design on the assumption of aspect ratio 2:1. Changing the fracture height to 300 ft, the theoretical optimum values become more realistic, because the decrease of volumetric proppant efficiency reduces the proppant number . Table 29. Theoretical optimum assuming 300 ft fracture height: LPF01-1 Optimum placement without constraints Proppant number, Nprop 0.4026 Dimensionless PI, JDopt 0.68 Optimal dimensionless fracture cond, CfDopt 1.8 Optimal half length, xfopt, ft 309.4 Optimal propped width, wopt, inch 0.1 Post treatment pseudo skin factor, sf -5.78 Folds of increase of PI 4.92 HF2D Page 65 Table 29. Actual placement assuming 300 ft fracture height but unchanged leakoff coefficient: LPF01-2 Actual placement Proppant mass placed (2 wing) 90,000 Proppant number, Nprop 0.4026 Dimensionless PI, JDact 0.68 Dimensionless fracture cond, CfD 1.8 Half length, xf, ft 309.4 Propped width, w, inch 0.06 Post treatment pseudo skin factor, sf -5.78 Folds of increase of PI 4.92 Treatment details Efficiency, eta, % 67.1 Pumping time, te, min 52.7 Pad pumping time, te, min 10.4 Exponent of added proppant concentration, eps 0.1966 Uniform proppant concentration in frac at end, lbm/ft^3 22.6 Areal proppant concentration after closure, lbm/ft^2 0.5 Max added proppant concentration, lb per gal clean fluid 3.5 Net pressure at end of pumping, psi 113.7 While the design is now more realistic, one variable deserves special attention. The fluid efficiency increased to 67 %. Why did this happen? The reason is that, according to our definition, leakoff happens only in the pay layer (with net thickness 76 ft). Now, that the actual fracture height is taken as 300 ft, only one quarter of the total surface contributes to leakoff and the efficiency is very high. In reality it is not likely, that perfectly non-permeable shale is surrounding the pay. Therefore it is wise to reconsider the leakoff (and spurt loss) parameters once a significant change in fracture height has been introduced. HF2D Page 66 Repeating the design with correspondingly adjusted leakoff and spurt loss coefficients: Leakoff coefficient in permeable layer, ft/min^0.5 0.0050 Spurt loss coefficient, Sp, gal/ft^2 0.00250 we obtain the results in Table 30. Table 30. Actual placement assuming 300 ft fracture height and adjusted leakoff and spurt loss coefficients: LPF01-3 Actual placement Proppant mass placed (2 wing) 90,000 Proppant number, Nprop 0.4026 Dimensionless PI, JDact 0.68 Dimensionless fracture cond, CfD 1.8 Half length, xf, ft 309.4 Propped width, w, inch 0.06 Post treatment pseudo skin factor, sf -5.78 Folds of increase of PI 4.92 Treatment details Efficiency, eta, % 38.2 Pumping time, te, min 92.8 Pad pumping time, te, min 41.5 Exponent of added proppant concentration, eps 0.4475 Uniform proppant concentration in frac at end, lbm/ft^3 22.6 Areal proppant concentration after closure, lbm/ft^2 0.5 Max added proppant concentration, lb per gal clean fluid 3.5 Net pressure at end of pumping, psi 113.7 HF2D Page 67 The fluid efficiency is more realistic now, but the final fracture length and propped width is exactly the same as previously. How is it possible that such a large change in the leakoff parameters does not affect the final results? The answer to this question reveals the main difference between simulation and design. In our design procedure the target length and target propped width are derived from the reservoir and proppant properties. The leakoff parameters (and other variables) determine how we achieve our final goal, but the goal is the same, whether there is intensive leakoff or not. The change in the leakoff parameters shows up in the actual proppant schedule. Now we have to pump for a considerably longer time. Experienced fracturing engineers would probably not accept the design yet. The point is that the indicated propped fracture width is only 0.06 inch, that is less than 3 grains of the 20/40 mesh proppant. A good design ensures a certain minimum width (or a certain minimum areal proppant concentration.) At this point we either increase the amount of proppant or depart from the indicated optimum length, now multiplying it by a factor less than one. The advantage of creating a shorter fracture shows up also in the volumetric proppant efficiency: in other words keeping the aspect ratio 2:1 we will have less proppant “avoiding” the pay. The relevant lines of the input are shown in Table 31. Table 31. Final design: LPF01-4 Proppant mass for (two wings), lbm 90,000 … Fracture height, ft 200.0 … Leakoff coefficient in permeable layer, ft/min^0.5 0.0050 Spurt loss coefficient, Sp, gal/ft^2 0.0025 Max possible added proppant concentration, lbm/gal neat fluid 12 Multiply opt length by factor 0.55 Multiply Nolte pad by factor 1 HF2D Page 68 Table 32. Actual placement: LPF01-4 Actual placement Proppant mass placed (2 wing) 90,000 Proppant number, Nprop 0.6039 Dimensionless PI, JDact 0.67 Dimensionless fracture cond, CfD 6.7 Half length, xf, ft 198.3 Propped width, w, inch 0.13 Post treatment pseudo skin factor, sf -5.76 Folds of increase of PI 4.85 Table 33. Some Details of the Actual placement: LPF01-4 Treatment details Efficiency, eta, % 38.3 Pumping time, te, min 38.5 Pad pumping time, te, min 17.2 Exponent of added proppant concentration, eps 0.4457 Uniform proppant concentration in frac at end, lbm/ft^3 54.3 Areal proppant concentration after closure, lbm/ft^2 1.1 Max added proppant concentration, lb per gal clean fluid 10.8 Net pressure at end of pumping, psi 166.4 Note that targeting the smaller fracture allowed us to reduce the assumed height as well. Therefore, the design can utilize more efficiently the 90,000 lbm proppant. The post-treatment dimensionless productivity index and equivalent skin factor are basically the same as in the case of LPF01-3. The final design, LPF01-4, is more practical and certainly easier to carry out. HF2D Page 69 A.9 Summary In this Appendix we showed some examples of practical fracture design. The concept of proppant number and dimensionless productivity index helped us to make important decisions without going into unnecessary details. The design spreadsheet was used extensively to consider what-if scenarios and investigate options. In hydraulic fracture design, where the reliability of the available input data is always limited and the process itself is inherently stochastic, it is extremely important to proceed in an evolutionary manner, continuously improving the design process. The simple spreadsheet does not substitute the sophisticated “3D” fracture simulators. Rather, it provides a flexible tool to make the basic decisions before the final design. HF2D Page 70