You are on page 1of 7

SPE 103184

Achieving Savings in Time-Sensitive Completion Costs: Results From Recent


Single-Trip Multizone Frac-Packing Case Histories
E. Van Sickle, SPE, A. Womble, SPE, and M. McKown, SPE, Baker Oil Tools

Copyright 2006, Society of Petroleum Engineers


This paper was prepared for presentation at the 2006 SPE Annual Technical Conference and
Exhibition held in San Antonio, Texas, U.S.A., 2427 September 2006.
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, as
presented, have not been reviewed by the Society of Petroleum Engineers and are subject to
correction by the author(s). The material, as presented, does not necessarily reflect any
position of the Society of Petroleum Engineers, its officers, or members. Papers presented at
SPE meetings are subject to publication review by Editorial Committees of the Society of
Petroleum Engineers. Electronic reproduction, distribution, or storage of any part of this paper
for commercial purposes 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 where and by whom the paper was presented. Write Librarian, SPE, P.O.
Box 833836, Richardson, TX 75083-3836, U.S.A., fax 01-972-952-9435.

Abstract
With rig costs and other time-sensitive completion costs rising, offshore
operators must continually find ways to reduce operating costs while
minimizing risk. Frac packing often involves expensive fluids, proppant
and equipment. Single-trip multi-zone sand control completion systems
are not new to the Gulf of Mexico, but the adaptation of these systems
to facilitate frac packing has created new opportunities for the
technology. Multi-zone, single-trip completion systems were first used
offshore California in the 1980s to reduce completion costs in marginal
fields. The initial system design was used successfully in several
hundred wells to complete more than 900 zones. In the early 1990s,
the system was modified to minimize rig time and reduce formation
damage in the Gulf of Mexico by reducing formation exposure time to
completion fluids. This paper will review the history of multi-zone,
single-trip completion systems and discuss how the systems were
adapted to facilitate frac packing, including modifications to allow for
high pump rates and large sand or proppant volumes. The paper will
also present detailed results of recent applications for several Gulf of
Mexico operators that demonstrate the advantages of the technology
over more conventional stack-pack completion methods.

Introduction
Single-trip, multiple-zone gravel pack systems are not new to the Gulf
of Mexico, but the adaptation to facilitate frac packing has created new
opportunities for this technology.
Single-trip, multi-zone (STMZ) gravel pack completions where first
designed in the early 1980s and initially utilized in the Beta field,
offshore California. This reservoir in the Beta field consisted of
unconsolidated sand containing 11 to 15 API gravity oil. The
productive interval was composed of as many as nine separate zones
with a gross interval thickness of 1200 feet, with the top pay as shallow
as 2700 feet. The system was designed to provide for zone isolation in
the form of packers without the normal packer slips, and hence the first
zone isolation packers were created. The gravel pack liner assembly
consisted of a series of screen / isolation packer / gravel pack port
combinations, one combination per zone. Seal bores were positioned
above each isolation packer and below the gravel pack port to be used
for positioning of a gravel pack seal assembly during gravel packing.

All producing zones where first perforated, simultaneously, with the


use of tubing-conveyed perforating guns. The appropriate number of
gravel pack assemblies was assembled together as a single unit and a
conventional gravel pack packer, with slips, was positioned at the top
gravel pack assembly. With the entire assembly assembled and
hanging in the rotary table, the gravel pack seal assembly and wash
pipe was lowered, on concentric tubing, thru the assembly until it was
positioned in the lower-most zone assembly, then attached to the
packer hydraulic setting tool. The STMZ system was then run to
bottom on drill pipe. Once positioned across from the producing
interval the upper gravel pack packer is set, the setting is released,
and the gravel pack seal assembly is used to hydraulically set all zone
isolation packers.
The gravel pack seal assembly was then
repositioned to the lower-most zone and wash pipe was run
concentrically thru the drill pipe to bottom and stung into the gravel
pack seal assembly, essentially creating an extremely long, sometimes
2700 feet in length, gravel pack crossover tool with the crossover port
in the gravel pack seal assembly and the circulating return port at the
rotary table. The lower-most zone was then gravel packed. Repositioning the tool to pack all upper zones required pulling both the
drill pipe and concentric wash pipe.
This original system, given the name Beta system in reference to the
field in which the system was utilized, was applied successfully in over
250 wells involving over 2000 zones from 1981 to 1991, some of which
is described by Jefferis et al1, with remarkable success resulting
significant completion time savings.

Evolution of the Technology for use in the Gulf of


Mexico
As drilling in the Gulf of Mexico moved to deeper water depths in the
early 1990s, operators began to look for additional methods to reduce
completion cost. The use of STMZ systems were investigated for use
as a means of reducing time-sensitive costs as well as minimizing both
completion fluid losses and the need for fluid loss circulation material.
Applications in the Gulf of Mexico presented significantly different
operational considerations when comparing the conditions of use of
the original Beta style STMZ system used previously in offshore
California.
Gulf of Mexico reservoirs consist of fluid sensitive
formations and higher bottomhole pressures than those experienced
with the original system, hence modifications to the system were
required in order to provide for complete zonal isolation throughout the
entire gravel packing process and prevent fluid loss to the lower zones
while gravel packing the upper zones. The result was a modified
Beta style STMZ system. While the gravel pack liner essentially
remained the same, the gravel pack tool and inner concentric pipe
assembly differed dramatically from the original Beta system. More
conventional-like crossover tool type system was incorporated,
shortening the effective length of the crossover tool by moving the
circulation return port to just above the upper-most gravel pack packer.
Now the crossover tool was essentially equal in length to the overall
gravel pack liner assembly and the need for concentric pipe run to the
surface was eliminated. In addition, by adding wash pipe in a length
equal to the longest interval length, to the bottom of the crossover
tools, zone isolation was achieved for lower zones while gravel packing
the upper zones.

This was a significant, although highly effective, modification to the


Beta system. However, because of the importance of wash pipe and
crossover tool positioning during the entire multi-zone gravel packing
process, pre-job planning and space out of the multiple seal
assemblies became much more critical than with the previous system.
Regardless, and with the utilization of dedicated and experienced
personnel, the system was successfully utilized on several projects in
2
the Gulf of Mexico, some of which are described by Brannon, et al.

Reduction in Completion Costs


Single-trip, multi-zone gravel pack and frac pack systems reduce
completions costs significantly. These savings are a result, primarily,
of reducing multiple requirements of three operations. First, since all
zones must be perforated at the same time, multiple perforating runs
can be reduced to a single tubing-conveyed perforating run and one
well-killing operation or possible well control situation. However, this
process limits the possible STMZ applications as now all zones must
be similar in pressure gradient, as the zones will be controlled using
the same fluid weight. Second, since all zones are now perforated at
the same time, the need for zone isolation during perforating is
eliminated therefore the running and retrieving of isolating packer plugs
is not required. Finally, and most obvious is the fact that all zones are
now gravel packed in the same single trip. This reduction in the
number of operations and tripping of drill pipe yields to significant
reduction in all time-sensitive cost, especially rig related costs.
Furthermore, with reduction in drill pipe trips per zone, there is far less
potential for fluid loss to each zone. Completion fluid costs are
minimized and the risk for possible formation damage is also further
reduced.
Also, because of the above mentioned reduction in
operations and the fact that time between treating each zone is
minimized, additional time sensitive savings are achieved when using
stimulation vessels for frac packing operations. Stimulation vessels
may now arrive on location, treat multiple zones with minimal down
time and then be release from location in a timelier manner.

Transitioning STMZ Technology for Frac Packing


Applications
With the introduction of frac packing technology to the unconsolidated
formations of the Gulf of Mexico, STMZ completion systems were once
again required to adapt to a higher operating environment. Several
modifications were made to the system to enable the higher operating
pressures, flow rates and proppant volumes required for frac packing
multiple zones in a single trip. Erosion resistant frac sleeves were
incorporated into the gravel pack system and the pressure rating of the
entire system, including the zone isolation packers, was upgraded to
13,000 PSI. In order to confirm frac packing crossover tool positioning
and to maintain tool position, a positive locking collet device was
incorporated into the system. This positioning collet allows the
crossover tool to be positioned and set-down weight maintained to
keep the tool in proper frac packing position throughout the entire
process. There is one indicator device located in each separate zone
assembly, Fig. 1. Proprietary software has been developed which
calculates the set-down force required to keep the positioning collet on
the indicator at each step of the frac packing procedure.
With the need to pump large frac proppant treatment volumes, not just
once but on multiple zones, the erosion resistance of the crossover
tool required upgrading. Advanced computational flow dynamic (CFD)
modeling was utilized to model downhole flow dynamics on the STMZ
system. Modifications were made to the crossover tool which will
enable to the tool to survive and function throughout the multi-zone
frac packing process. So far, to date, the maximum proppant volume
pumped in one STMZ application has been 211,200 lbs. Fig. 2 details
several of the technical modifications to convert to a frac rated STMZ
system.

Case Histories
The STMZ system has been utilized successfully in several areas,
primarily in Bohai Bay, China, Alaska, and the Gulf of Mexico. The
system has been utilized in the Bohai Bay area to successfully
complete 1100 zones for several operators. To date there have been
nine runs of the STMZ frac pack system in the Gulf of Mexico, eight of
which were executed flawlessly. Several Gulf of Mexico case histories

SPE 103184

will now be discussed in detail, including the one application in which


execution problems were experienced. These applications were
chosen as case histories in order to illustrate the versatility and
flexibility of the STMZ system.
Case 1: An operator in the Ship Shoal area installed a 3 zone gravel
pack assembly in a single trip, to a depth of 12,438 ft. using the STMZ
Frac system. The MZ Crossover tool functioned properly by setting
and testing three packers, positively locating all treatment positions,
and directing fluid and slurry as designed.
Acid stimulation and gravel pack treatments were individually placed in
the three isolated sands. The lower zone sand treatment was pumped
at relatively high injection pressures (5 bpm, 1 bpm returns, and 4456
psi) after a minimal response to a mud acid treatment. An early (6396
psi) screen out occurred and 2448 lbs. of the 2 PPA, 3412 lbs slurry
was reversed out. The screen / casing annulus was packed with 664
lbs of sand, covering the screen and 16.3 ft of blank. Sand placement
in the perforations was calculated to be 300 lbs. of sand which is 18.7
lbs/ft MD and 27.28 lbs/ft TVD.
The crossover tool was repositioned to the middle zone treatment
position. The middle zone packer was set and tested as designed. The
treatment was pumped with relatively high injection pressures (5 bpm,
1 bpm returns, and 4507 psi) after a minimal response to a mud acid
treatment. The screen out occurred and 950 lbs. of the 2 PPA, 2370
lbs slurry was reversed out. The screen / casing annulus was packed
with 552 lbs of sand, covering the screen and 13.5 ft of blank pipe.
Sand placement in the perforations was calculated to be 868 lbs. of
sand which is 108.4 lbs/ft MD and 145 lbs/ft TVD.
The crossover tool was then repositioned to the upper zone treatment
position. The upper zone packer had been set prior to releasing the
service tool, so the sand treatment was pumped in the set down
circulating position in the upper zone. Lower injection pressure were
initially observed (3824 psi) but increased to 5212 psi at 6 bpm, with 1
bpm return rate, while pumping the 5501 lbs slurry. A 6016 psi sand
out occurred at 1bpm, and 2500 lbs of sand was reversed out. There
was initially difficulty moving the slurry in reverse, but an additional 3 ft
of upward crossover tool movement, allowed for returns. The screen
and blank was packed with 677 and 223 lbs of sand respectively,
covering 15.3 ft of blank. Sand placement in the perforations was
calculated to be 2100 lbs. of sand which is 52.5 lbs/ft MD and 75 lbs/ft
TVD.
The STMZ crossover tool was removed from the packer assembly
without incident and the fluid losses increased to 75 bph. Mechanical
fluid loss control devices are compatible with the STMZ frac pack
system and were available but were not selected. A 50 bbl. HEC Gel
pill was pumped through the service tool which eliminated the fluid
losses. Fig. 3 details a comparison in completion time between the
completion time using the STMZ frac system with that of well in the
same are using a conventional stack pack completion method.
Case 2:
An operator in the West Delta area had a workover which required two
zones to be frac packed. The selected zones were located above and
below an existing depleted zone which was previously gravel packed.
The existing gravel pack equipment was retrieved and the existing
perforations were squeezed off. The decision was made to utilize the
STMZ frac system in order to frac pack the lower zone using a live
annulus while isolating the squeezed perforations to prevent them from
breaking down during the fracture treatment or during the reversing of
the lower frac treatment.
The new zones were first perforated on wireline. The STMZ assembly
was run to a depth of 10,050 ft MD. The STMZ frac system crossover
tool functioned properly, by setting and testing the packers, positively
locating all treatment positions, and directing fluid and slurry as
designed. Acid treatments were pumped ahead of each frac pack
treatment and both were individually placed in the 2 isolated sands.
The lower zone frac treatment was pumped at an average surface
treating pressure of 5654 psi (max 8152 psi) at an average rate of 12
bpm. Proppant volume of 1,350 lbs was reversed out after the screen

SPE 103184

out. A total of 17,821 lbs of proppant was placed below the crossover
tool, 615 lbs covering the screen and blank and 688 lbs/ft MD and 860
lbs/ft TVD in the perforations.
The crossover tool was repositioned 63 feet uphole and the middle
isolation packer was set and tested. The crossover tool was then
repositioned 200 feet uphole to the upper zone treatment position.
The upper zone frac treatment was pumped at an average surface
treating pressure of 6000 psi (max 8240 psi) at an average rate of 12
bpm. A hard sand out occurred with 7 ppa slurry back to the frac
vessel and 10,640 lbs of proppant was reversed out after the screen
out. A total of 5,071 lbs of proppant was placed below the crossover
tool, 726 lbs covering the screen and blank and 217 lbs/ft MD and TVD
in the perforations.
The STMZ crossover tool was removed from the packer assembly
without incident and the fluid losses increased to above 75 bph. Again
the mechanical fluid loss device was not selected to control losses so
LCM was pumped to control the losses. A dual completion string was
then run for final production.
Brief Timeline:
Day 1:
21:00 hrs. - Running Mill through perf zones

below the crossover tool, 819 lbs covering the screen and blank and
210 lbs/ft MD and 236 lbs/ft TVD in the perforations.
The crossover tool was then repositioned 125 feet uphole to the upper
zone treatment position. The upper zone frac treatment was pumped
at an average surface treating pressure of 4250 psi (max 5210 psi) at
an average rate of 12 bpm and 4,446 lbs of proppant was reversed out
after the screen out. A total of 45,263 lbs of proppant was placed
below the crossover tool, 885 lbs covering the screen and blank and
644 lbs/ft MD and 726 lbs/ft TVD in the perforations.
The STMZ Crossover Tool was removed from the Packer assembly
without incident. A mechanical fluid loss device was ran and worked
properly, however the decision was made to open the fluid loss device
prior to tripping out of the hole with the STMZ Crossover Tool. An
LCM was pumped to control the losses. The single production string
was run utilizing the seal bores of the STMZ assembly and sliding
sleeves for selective production of the four zones without incident.

Brief Timeline:
Day 1:
20:15 hrs. - Set sump packer
Day 2:

11:45 hrs. - Fired guns for lower zone

Day 3:

10:30 hrs. - Surged well

20:30 hrs. - MU and RIH with 2 zone STMZ frac assembly w/


isolation (longer than usual time to PU equipment due to
transferring from lift boat)

Day 4:

12:45 hrs. - Finished cleaning out to sump

Day 5:

23:22 hrs. - Set lower frac packer

Day 4:

11:12 hrs. - Set upper packer


14:00 hrs. - Set and test lower zone isolation packer

Day 6:

19:30 hrs. - Finished GP and POOH w/ crossover tool

Day 7:

23:54 hrs. - Set and tested spacer assembly

Day 5:

01:07 hrs. - Sand out on lower zone of STMZ


02:58 hrs. - Set and test middle zone isolation packer
06:40 hrs. - Sand out on upper zone of STMZ

Day 8:

13:30 hrs. - Set packer plug, dumped sand, prepare to test


BOPs

Day 9:

21:25 hrs. - Fired guns perforating the 3 zones for the STMZ

Day 10:

15:30 hrs. - Cleaned out to packer, ran mill to clean up


perforations

Day 11:

18:19 hrs. - POOH with packer plug

Day 12:

09:30 hrs. - Made additional cleanup run to ensure seal bore


in spacer assembly was clear

Day 13:

22:30 hrs. - MU and RIH with 3 zone STMZ Frac assembly

Day 14:

12:54 hrs. - Set upper packer


14:25 hrs. - Set and test lower zone Isolation packer
23:34 hrs. - Sand out on lower zone of STMZ

Day 15:

02:35 hrs. - Set and test middle zone isolation packer


08:29 hrs. - Sand out on middle zone of STMZ
10:50 hrs. - Set and test upper zone isolation packer
16:35 hrs. - Sand out on upper zone of STMZ
23:00 hrs. - POOH with STMZ crossover tool

Day 2:

Day 3:

Day 6:

22:30 hrs. - Start in hole w/ sump set on E-Line (weather


delay)

05:30 hrs. - After pumping several pills to control fluid loss


POOH

Total time to run STMZ frac system and perform frac pack treatment
on three individual zones: 34 hours, 10 minutes.

Case 3: An operator in the West Delta area had a long producing


sand that would be difficult to frac the entire interval with a single frac
treatment. There was also another fairly long, higher pressured sand
approximately 1,500 ft below the upper sand. The lower sand was
completed using the conventional method of perforating, surging and
running a dedicated frac assembly with a concentric string for both
zonal isolation and future selective production. Due to abnormally high
treating pressures, a HRWP was performed on the lower zone in place
of the planned frac pack. Then a spacer packer assembly was run for
spacing and conduit to the lower sand. A three zone STMZ frac
assembly was then run to complete the long upper sand and frac pack
treatments were executed on all 3 zones. Finally the single production
string was run utilizing the seal bores of the STMZ frac assembly using
sliding sleeves for selective production.
The STMZ tools were ran to a depth of 9,800 ft MD. The spearhead
acid / frac pack treatments were individually placed in the three
isolated sands. The lower zone frac treatment was pumped at an
average surface treating pressure of 4250 psi (max 5210 psi) at an
average rate of 12 bpm and 4,446 lbs of proppant was reversed out
after the screen out. A total of 40,817 lbs of proppant was placed
below the crossover tool, 884 lbs covering the screen and blank and
644 lbs/ft MD and 726 lbs/ft TVD in the perforations.
The crossover tool was then repositioned 129 feet uphole to the middle
zone treatment position. The middle zone frac treatment was pumped
at an average surface treating pressure of 4500 psi (max 7000 psi) at
an average rate of 15 bpm and 16,999 lbs of proppant was reversed
out after the screen out. A total of 17,610 lbs of proppant was placed

Total time to run STMZ frac system and perform frac pack treatment
on three individual zones: 42 hours, 5 minutes.
Case 4:
This case history was chosen for inclusion in this paper as it reflects
the ability of the system to be retrieved with conventional fishing
operations. A three-zone STMZ system was run and positioned in
place; both the upper packer and the lower zone isolation packer were
set successfully. Frac packing operations were commenced on the
lower zone. Unfortunately the crossover tool was not positioned to the
reverse position in a timely manner, resulting in the tool becoming
stuck in the frac pack position with approximately 200 feet of sand still
in the drill pipe.

Fishing operations were begun immediately. First sufficient tension


was exerted on the workstring until the wash pipe parted. The drill
pipe was pulled out of the hole, retrieving the upper packer setting tool,
the 1.900 inner concentric pipe, and a section of the 2-7/8 wash pipe
down to the middle zone isolation seals. A packer retrieving tool was
run in the hole, latched into and released the upper packer and liner
assembly to the safety joint. Next an overshot was run and located on
the lower sub of the safety joint. Right hand rotation released the
safety sub immediately above the uppermost zone isolation packer and
that assembly was retrieved. A taper tap was then run and stabbed
into the zone isolation packer and the upper zone section of the STMZ
frac system was retrieved. This procedure now exposed the stuck 27/8 wash pipe / crossover tool assembly. Attempts to jar the assembly
were unsuccessful and a cut was made in the 2-7/8 wash pipe to a
depth below the middle zone STMZ frac assembly. This assembly was
then retrieved. Two more back off trips were required to retrieve
additional 2-7/8 wash pipe and the STMZ crossover tool, leaving a
section of the lower wash pipe in the lower zone. The upper two zones
were then completed with conventional stacked and frac packed
completions.
Conclusions:
1. Field tried and successful multi-zone systems can
successfully be modified and used to enable the application

SPE 103184

2.

3.

4.
5.

of frac pack treatments.


The STMZ frac system can be modified to successfully treat
multiple zones and is capable of pumping well over 220,000
lbs. of proppant.
The STMZ frac system can be modified to include isolation
assembles in order to isolate squeezed perforations in
necessary.
The STMZ frac system can be successfully installed above
conventional gravel packed zone assembly.
The STMZ frac system can be successfully fished from the
wellbore in the unfortunate event of crossover sticking during
a frac pack treatment.

References
1. Jefferis, R.G., Bruist, E.H., and Botts, T.M.: A Field Proven System
for Selective, Multizone, One-Trip Gravel packing, Paper SPE 11697
presented at the 1983 California Regional Meeting, Ventura, CA,
March 23-25, 1983.
2. Brannon, D.H., Harrison, D.T., and Van Sickle, E.W.: A Single-Trip,
Dual-Zone Gravel Pack System Successfully Gravel Packs Green
Canyon Area Wells, Gulf of Mexico, Paper SPE 21670 presented at
the Production Operations Symposium, Oklahoma City, OK, April 7-9,
1991.

SPE 103184

Fig. 1 STMZ Frac Pack System

SPE 103184

Return bypass
port opens to
allow circulation
and to monitor
frac treatment
of lower
interval. The top
interval is
Iiolated from
any pressure
associated with
this operation.

MZ-Frac Tool
is positioned
mechanically
with the
bypass
crossover port
sealed inside
of the isolation
packer.
Pressure is
applied to
actuate the
setting piston
in the packer.

MZ-Frac
Crossover Tool is
held in Positioned
with Set down
Weigh by the
Hydraulically
Activated Collet.
This insures tool
position
maintenance
during the
treatment of the
interval.

Fig. 2 STMZ Frac Pack System Details

Reverse
circulation is
established by
closing the
pipe rams at
surface and
pumping down
the annulus.
The fluid enters
the return
bypass port
and flows down
the miniannulus of the
service tool
string. The top
interval is
Iiolated from
any pressure
associated with
this operation.

The Service
Tool string is
raised from the
circulating
position until the
evacuation port
comes into
communication
with the bypass
crossover port.
During this step,
the sliding
sleeve is closed
and reverse
circulation is
established.

SPE 103184

Rig time and Trip


Comparison
Event Summary

Total
time to run STMZ frac
system and perform frac
pack treatment on three
individual zones: 48.5 hours

Conventional
Stack Pack
(hrs)

STMZ Frac
System
Actual (hrs)

Set Sump Packer Eline


Perforate Lower Zone
TCP

36

n/a

Perforate E-line(all
zones)

n/a

11.5

Clean Up all
Perforated Intervals

n/a

24

Gravel Pack Lower


Zone / MZ

38

79

36
14

n/a
n/a

38

n/a

36
14

n/a
n/a

38
254

n/a
118.5
135.5
114%

Set Packer
Plug/Perforate Middle
Zone
Retrieve Packer Plug
Gravel Pack middle
Zone
Set Packer
Plug/Perforate Middle
Zone
Retrieve Packer Plug
Gravel Pack Upper
Zone
TOTALS (hours)
Time Saving hrs.
Time Saving %
Fig. 3 Time Comparison

You might also like