Appendix: Evolution of Hydraulic Fracturing Design and Evaluation
Appendix: Evolution of Hydraulic Fracturing Design and Evaluation
Appendix: Evolution of Hydraulic Fracturing Design and Evaluation
Overview
This Appendix to Chapter 5 reviews the evolution
of hydraulic fracturing design and evaluation
methods. Complementary reviews are the application of fracturing by Smith and Hannah (1996) and
fracturing fluids by Jennings (1996). This review of
design and evaluation considers three generations of
fracturing: damage bypass, massive treatments and
tip-screenout (TSO) treatments.
The first two generations of fracturing and their
links to practices are emphasized because these contributions are not likely well known by the current
generation of engineers. The review focuses on
propped fracturing and does not explicitly consider
acid fracturing. Although the principles governing
the mechanics of both are essentially the same, the
fluid chemistry for obtaining fracture conductivity
is quite different (see Chapter 7). These principles
have their roots in civil and mechanical engineering,
more specifically in the general area of applied
mechanics: solid mechanics for the rock deformation and fluid mechanics for the flow within the
fracture and porous media. For the porous media
aspects, fracturing evaluation has benefited greatly
from the reservoir engineering practices discussed
in Chapters 2 and 12.
This review reflects the authors perspective and
bias in interpreting the impact of past contributions,
and therefore parts of this review should be anticipated to raise objections from others with an extensive knowledge of fracturing. In addition to this
volume, the Society of Petroleum Engineers (SPE)
Monograph Recent Advances in Hydraulic Fracturing (Gidley et al., 1989) provides balanced,
detailed coverage of the diverse areas of fracturing
from the perspectives of more than 30 fracturing
specialists.
This review concludes with speculation concerning a future generation, in which fracture design and
reservoir engineering merge into fracturing for
Reservoir Stimulation
reservoir management (i.e., control of both the vertical and horizontal flow profiles within the reservoir). Similar speculation in a 1985 lecture suggested that development of the technical foundation
for the TSO generation would quickly bring higher
permeability formations into consideration as typical
fracturing candidates (i.e., moderate k (2) on
Appendix Fig. 1a, with 2 indicating a target for
folds of increase [FOI] in the production rate, in
contrast to 10 for tight gas and massive treatments). However, the advent of this generation was
considerably delayed because of two factors that
have generally dominated technical considerations
during the history of fracturing. These dominating
factors are hydrocarbon prices and resistance to trying something new until established practices fail to
allow the economic development of a prospect.
The cycles of fracturing activity in Appendix Fig.
1a clearly reflect the timing of the first two fracturing generations. Appendix Fig. 1b identifies economic drivers for corresponding cycles in the U.S.
rig count. The first surge of activity resulted when
rotary drilling was introduced, which enabled the
development of deeper reserves. Fracturing activity
followed this trend soon after its commercialization
in 1949 because it was found to be an effective,
low-cost means of mitigating the resulting drilling
mud damage to reservoir sections (i.e., the damage
bypass generation). Both drilling and fracturing
activities began a long-term decline after 1955
because of degrading prices caused by imported oil
and regulated gas prices. Similarly, both activities
began a rapid increase at about 1979 as prices
increased because the Organization of Petroleum
Exporting Countries (OPEC) reduced its oil supplies
and a natural gas shortage developed in the United
States. The gas shortage, and its 10-fold-plus
increase in price, encouraged the development of
tight gas reserves and an associated demand for
massive fracturing treatments to develop the tight
reserves. The failure of past fracturing practices for
A5-1
(a)
Mode
rate k
(2)
High c
onduc
tivity
Un
T
de ight
rst
ga
an
s(
eq ding 10)
uip , m
me ate
nt
ria
ls,
Rem
ove
dam
age
Treatments
4000
0
1950 1955
1971
Year
1981
15.1
Up
Up
9.
9%
/y
ea
r
%/y
ear
4500
OPEC overextends
4000
Prices fall
U.S. gas prices regulated
Middle
East
discoveries
3500
3000
U.S. production peaks
OPEC develops
2500
price authority
Do
wn
2000
6.
1%
/ye
1500
ar
1000
Rotary displaces
500
cable tool drilling
0
1940 1950 1960 1970 1980
.5%/yea
Down 25
The beginning
(b)
1990
2000
Year
Appendix Figure 1. (a) Trends in fracturing activity treatments per month (courtesy of K. G. Nolte and M. B. Smith,
19851986 SPE Distinguished Lecture). (b) U.S. drilling rig
activity shows five major trends (updated from Oil & Gas
Journal, 1985).
A5-2
packing to achieve low-skin completions for a significant venture in the Gulf of Mexico.
The potential for a future reservoir management
generation was demonstrated in 1994 for the Norwegian Gullfaks field. The potential is to use TSO
treatments and indirect vertical fracturing for
increased reserves recovery, formation solids control
and water management. However, the unique benefits and favorable economics for this different
approach to reservoir plumbing were slow to
materialize because of the industrys comfort with
deviated drilling and more traditional completions.
Another observation from this historical perspective is the 1985 forecast of a flat drilling level
(Appendix Fig. 1b). However, activity continued to
decrease rapidly, to less than one-half of the forecast,
and subsequently declined by another one-half. Stable
activity levels within the petroleum industry are not
seen in the historical cycles and remain the product
of wishful thinking.
The concept of hydraulic fracturing within the petroleum industry was developed during the last half of
the 1940s within Stanolind (now BP Amoco; e.g.,
Clark, 1949; Farris, 1953; Howard and Fasts
Hydraulic Fracturing Monograph, 1970) by building
on the industrys experience with injection techniques that had experienced increased injectivity
by fracturing: acidizing (Grebe and Stoesser, 1935),
squeeze cementing and brine injection wells. A reissued patent was granted (Farris, 1953, resulting
from an initial filing in 1948) that was comprehensive in scope and covered many recognized practices
and products: proppant, gelled oil, breakers, fluidloss additives, continuous mixing, pad-acid fracturing, emulsified acids and the use of packers for fracturing multiple zones. Several aspects of the patent
that later became important included the implication
that fractures were horizontal and the use of a lowpenetrating fluid or with viscosity > 30 cp.
The first experimental treatments were performed
in 1947 on four carbonate zones in the Houghton
field in Kansas (Howard and Fast, 1970). The zones
had been previously acidized and were isolated by a
cup-type straddle packer as each was treated with
1000 gal of napalm-thickened gasoline followed by
2000 gal of gasoline as a breaker. These unpropped
Reservoir Stimulation
worthy design and evaluation methods from this generation are fracture orientation (horizontal or vertical), in-situ stress and fracture width models, FOI
prediction and fracture conductivity in production
enhancement.
A5-3
h = Ko v ,
(1)
A5-4
L=
Vi
2hf (w + CL 8t )
=
2hf wL
Vi
Fluid loss
CL t
Proppant
Geometry
hf
2L
Proppant
(% area = )
w
Pad
Volume
Appendix Figure 2. Volume balance for fracture placement (equation from Harrington et al., 1973) (adapted
courtesy of K. G. Nolte and M. B. Smith, 19841985 SPE
Distinguished Lecture).
(2)
where Ko = 13 with = 30. For this case the horizontal stress is much less than the vertical stress except
in the extreme geopressure case of pore pressure
approaching overburden, which causes all stresses
and pore pressure to converge to the overburden
stress. For the thrust faulting case, the larger horizontal stress (i.e., for the two horizontal directions) is
greater than the overburden and the smaller horizontal stress is equal to or greater than the overburden.
Both the extreme geopressure case and an active
thrust faulting regime can lead to either vertical or
horizontal fractures. The author has found Appendix
Eq. 2 to accurately predict the horizontal stress in tectonically relaxed sandstone formations ranging from
microdarcy to darcy permeability. The accuracy at
the high range is not surprising, as the formations
approach the unconsolidated sand in the sandbox
experiments. The accuracy obtained for microdarcypermeability sands is subsequently explained.
Reservoir Stimulation
A5-5
10,000
50
8000
Crosslinked gel
40
Injection
Step rate
Linear gel
6000
30
4000
20
Injection
Step rate
Minifracture
Propped fracture
2000
Linear gel
10
BHP
Injection rate
0
0
0.5
1.0
2.0
13.0
13.5
0
14.0
Time (hr)
Appendix Figure 3. High-permeability frac and pack treatment (Gulrajani et al., 1997b).
A5-6
Width models
The first rigorous coupling of fluid flow and the elastic response of the formation was reported by
Khristianovich and Zheltov (1955). They used a twodimensional (2D) formulation based on a complex
variable analysis. Their formulation was equivalent
to the length becoming the characteristic, or smaller,
dimension and provides the initial K for the KGD
width model discussed later and in Chapter 6. In
addition to being the first paper to provide the coupling of fluid flow and rock interaction that is the
embodiment of the hydraulic fracturing process, the
paper also identified the role for a fluid lag region at
the fracture tip. This low-pressure region, beyond the
reach of fracturing fluid and filling with pore fluid,
has a large, negative net pressure and acts as a clamp
at the fracture tip. The fluid lags clamping effect
provides the natural means to lower the potentially
Reservoir Stimulation
large tip-region stresses to a level that can be accommodated by the in-situ condition. The presence of
the lag region has been demonstrated by field experiments at a depth of 1400 ft at the U.S. Department of
Energy (DOE) Nevada Test Site (Warpinski, 1985).
Appendix Fig. 4 compares the Khristianovich and
Zheltov analytical results for width and pressure to
the corresponding parameters from the Warpinski
field results. For the analytical results, decreasing
values of the complex variable angle 0 toward the
right side of the figure correspond to relatively
smaller lag regions and larger differences between
the minimum stress and pressure in the lag region
(i.e., generally deeper formations). The width profiles clearly show the clamping action at the tip, and
the field data appear to be represented by a 0 valve
of about /8 for the analytical cases. Also noteworthy of the experimental results is that tests 4 through
7 with water and test 9 with gel show similar behavior when test 4, which had a relatively low injection
rate, is ignored. Tests 10 and 11 were with a gelled
fluid and clearly show progressively different behavior from the preceding tests because of the altered tip
behavior resulting from prior gel injections and the
residual gel filter cakes that fill the fracture aperture
after closure. The cakes have the consistency of silicon rubber and functionally provide an analogous
sealing affect for subsequent tests.
The practical importance of the lag region cannot
be overemphasized. The extent of the region, which
is extremely small in comparison with commercialscale fractures, adjusts to the degree required to
essentially eliminate the role of the rocks fracture
resistance or toughness (e.g., see SCR Geomechanics
Group, 1993) and to isolate the fluid path from all
but the primary opening within the multitude of
cracks (process zone) forming ahead of the fracture
(see Chapters 3 and 6). The field data show the
width at the fluid front is well established (i.e., generally greater than 5% of the maximum width at the
wellbore) and that fluid enters only a well-established
channel behind the complexity of the process zone.
These aspects of the lag region provide great simplification and increased predictablility for applying
commercial-scale hydraulic fracturing processes.
A paper by Howard and Fast (1957), and particularly the accompanying appendix by R. D. Carter,
provides the current framework for fluid loss. The
paper identifies the three factors controlling fluid
loss: filter-cake accumulation, filtrate resistance into
A5-7
0.6
1.0
Test
4
5
6
7
9
10
11
0.5
0.4
0.9
0.8
0 = 3
16
0.7
0 =
8
w/wo
w/wo
0.6
0.3
Width at
fluid arrival
0 =
4
0.4
0.2
0 =
16
0 = 3
8
0.5
0.3
0.2
0.1
0.1
0
0.25
0
0.20
0.15
0.10
0.05
1.0
1.0
Test
4
5
6
7
9
10
0.8
0.8
0 =
8
0 = 3
8
p/po
0.6
p/po
0.6
0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
0.4
0 =
16
0.4
0 =
4
0.2
0.2
0 = 3
16
0
0.5
0
0.4
0.3
0.2
0.1
0.2
0.4
0.6
0.8
1.0
Appendix Figure 4. Comparison of Warpinski (1985) field data (left) and Khristianovich and Zheltov (1955) analysis
(right). wo and po are the wellbore values of width and pressure, respectively; x is the distance from the well.
A5-8
Reservoir Stimulation
A5-9
(J/Jo)
7.13
re
ln 0.472 rw
14
L/re = 1
12
10
8
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
2
0
102
103
104
Relative conductivity,
105
kfw
k
106
40
A5-10
1.0
Effective wellbore radius, rw/xf
rw = 0.5x f
0.5
1
rw = 0.28
k fw
k
CfD = 30
0. 1
0.01
0.1
CfD =
CfD = 0.2
1.0
k fw
kx f
10
100
Treatment optimization
Optimizing a fracture treatment is an essential part
of maximizing its benefit (see Chapters 5 and 10).
For this reason Prats (1961) optimization consideration is of historic importance, although proppant volume is generally not a realistic criterion because
proppant cost is only part of the investment for a
fracture treatment (e.g., Veatch, 1986; Meng and
Brown, 1987). Prats proppant optimization condition at CfD = 1.26 could be a practical target for
high-permeability reservoirs; however, this value is
about an order of magnitude lower than the optimum
case for the long transient period of a very low permeability reservoir.
Additional lessons are also provided by the apparentwellbore concept. The first is that a fracture is
equivalent to enlarging the wellbore and not increasing the formations global permeability. Incorrectly
considering a fracture to be a permeability increase
can lead to incorrect conclusions concerning reservoir recovery and waterflood sweep. Another insight
is the generally favorable economics for an effectively designed and executed fracture. A fracture
Reservoir Stimulation
A5-11
(3)
A5-12
Reservoir Stimulation
A5-13
Inferred pressure
9000
Fracture
treatment
Pressure decline
Fracture
Transient reservoir
closing
pressure near wellbore
8000
7000
6000
Fracture closes on
proppant at well
Net fracture
pressure
pnet = pw pc
Closure pressure
pc = horizontal rock stress
Reservoir pressure
5000
38
40
42
44
46
48
50
56
58
A5-14
(4)
1
1 dw
=
for constant h and L.
w dpnet
pnet
(5)
Fracture simulators
Describing a hydraulic fracture produces a significantly more complex role for the diffusive process
than the reservoir case because the basic parameter
groups change continuously with time, with a nonlinearity for the equivalent permeability, and the farfield elastic coupling between width and pressure
produces local parameters that have a general dependence on the pressure everywhere within the fractures unknown boundaries. For these reasons, fracture simulators that rigorously and robustly couple
these parameters in a general manner (see Section
6-3) have not progressed at the same rate as reservoir
simulators.
The modeling difficulties led to widespread use of
simulators based on P3D assumptions that partially
circumvent the far-field elastic-coupling condition.
The two most common means were relaxing the lateral coupling in the long direction of the fracture (as
for the PKN model) to allow a cellular representation
and vertical height growth of the cells (e.g., Nolte,
1982) or prescribing the boundary and width profiles
by elliptical segments and a lumped dependence on
the governing parameters (e.g., Settari and Cleary,
1986). P3D models, or more precisely P2D models,
evolved to include automated proppant scheduling
and the temperature-exposure history for polymer and
additive scheduling (e.g., Nolte, 1982), acid fracturing (e.g., Mack and Elbel, 1994), economic optimization for treatment design (e.g., Veatch 1986; Meng
and Brown, 1987), automated pressure-history matching (e.g., Gulrajani and Romero, 1996; Gulrajani et
al., 1997b) and rigorous 2D slurry flow (e.g., Smith
and Klein, 1995).
Originally restricted to in-office use, these models
merged with on-site fracture monitoring systems to
provide treatment evaluation and simulation in realtime mode. An equally important advance was the
parallel evolution of process-controlled mixing and
blending equipment for reliable execution of more
demanding treatment schedules and progressively
more complex chemistry that requires precise proportioning (see Chapters 7 and 11).
Reservoir Stimulation
A5-15
2000
Proppant
begins
II
1000
II
500
40
III-a
Proppant
begins
II
[5 MPa]
60
III-b
IV
III-a
100
200
400
600
1000
Time (min)
Idealized Data
log pnet
Field Data
Net pressure, pnet (psi)
III-b
II
III-a
IV
Inefficient extension for
pnet formation capacity pfc
capacity. The capacity (Nolte, 1982) defines the pressure limit for efficient fracture extension and is analogous to the pressure-capacity rating for a pressure
vessel. The cited reference has an unsurprising
theme of the negative effects of excesses of pressure,
polymer and viscosity.
Three mechanisms for a formation can define its
pressure capacity before rupture accelerates fluid
loss from the formations pay zone. The subsequent
fluid loss also leaves proppant behind to further
enhance slurry dehydration and proppant bridging.
Each mechanism is defined by the in-situ stress state
and results in a constant injection pressure condition,
or zero log-log slope, when the net pressure reaches
the mechanisms initiation pressure. The mechanisims are
Appendix Table 1. Slopes of fracturing pressures and their interpretation in Appendix Fig. 8.
Type
Interpretation
8 to 14
II
III-a
III-b
IV
Negative
A5-16
opening the natural fissures in the formation, governed by the difference in the horizontal stresses
extending the height through a vertical stress barrier and into a lower stress (and most likely permeable) zone, governed by the difference in the
horizontal stress for the barrier and pay zone
initiating a horizontal fracture component when
the pressure increases to exceed the level of the
overburden stress.
An important observation for the pressure capacity
is that it depends on the in-situ stress state and therefore does not change for the formation in other well
locations unless there are significant local tectonic
effects. As a result, all future treatments for the field
can generally be effectively designed on the basis of
only one bottomhole pressure recording and its
detailed analysis (see Section 9-4).
The upper curve on Appendix Fig. 8, for the
Wattenberg treatment, illustrates the fissure-opening
mechanism with the Type II zero slope occurring at
a net pressure of 1700 psi. This value provides one of
the largest formation capacities ever reported. The fissure opening is preceded by restricted height growth
and unrestricted extension (Type I slope) that provide
the most efficient mode of fracture extension. Therefore, conditions in this formation are favorable for
propagating a massive fracture; not by coincidence,
this was the first field successfully developed in the
massive treatment generation (Fast et al., 1997), and it
provided incentive to continue the development of
massive treatment technology. Returning to Appendix
Fig. 8, after the period of constant pressure and
enhanced fluid loss, a Type III-a slope for a fracture
screenout occurs because slurry dehydration forms
frictional proppant bridges that stop additional extension (i.e., a generally undesired screenout for a tight
formation requiring fracture length over conductivity).
After the penetration is arrested, the major portion of
the fluid injected is stored by increasing width (see
Appendix Eq. 4) and the net pressure develops the unit
slope characteristic of storage. The amount of width
increase is proportional to the net pressure increase.
The Wattenberg treatment consisted of 300,000 gal
of fluid and 600,000 lbm of sand with an average
concentration of 2 ppa, similar to the previous example. However, the treatment was successful because
a polymer-emulsion fluid with low proppant pack
damage was used. After the treatment defined the
formation capacity, model simulations indicated that
Reservoir Stimulation
A5-17
Subsequent treatments were improved after understanding the formations pressure behavior as in the
Wattenberg case and for this area after understanding
the implications of Appendix Eq. 3 for concentrating
polymer. In addition, the observation that proppant
bridging could restrict height growth was developed
for treatments to mitigate height growth (Nolte,
1982). An effective and relatively impermeable
bridge can be formed within the pinch point to retard
height growth by mixing a range of coarse and fine
sand for the first sand stage after the pad fluid.
Smith et al. (1984) later sought a means to significantly increase fracture width for the development of
a chalk formation within the Valhall field in the
Norwegian sector of the North Sea. The additional
width was required because laboratory tests indicated
the likelihood of substantial proppant embedment
into the soft formation that would lead to the loss of
effective propped width. Fracturing was considered
for this formation because other completion techniques would not sustain production because of chalk
flow. The resulting treatment design was based on the
behavior on the log-log plot in Appendix Fig. 8 for
the sand-disposal treatment: a purpose-designed TSO
treatment. For the disposal treatment, they observed
that after the initial screenout occurred, 2 million lbm
of proppant could be placed, and the net pressure
increase indicated that this occurred by doubling the
width after the screenout initiated.
Smith et al. designed and successfully placed a
TSO treatment in which proppant reached the tip and
bridged to increase the width by a factor of 2 during
continued slurry injection after the purpose-designed
TSO occurred. This design, with successful placement of progressively larger propped width increases,
became the tool that enabled the development of this
formation. The ability to significantly increase the
width after screenout results from the large storage
capacity of a fracture, as detailed in the discussion
following Appendix Eqs. 4 and 5. Additional discussion on the fracture completion in Valhall field and
the TSO treatment is in the Reservoir and Water
Management by Indirect Fracturing section.
As a historical note, a similar concept for a TSO
was disclosed in a 1970 patent (Graham et al.,
1972), with the bridging material consisting of petroleum coke particles (approximately neutral density to
ensure transport to the extremities). The patents goal
was increased width to enable placing larger size
proppant in the fracture.
A5-18
Deep damage
Fracturing in Prudhoe Bay was particularly successful
because deep formation damage induced by prior production (i.e., beyond the reach of matrix treatments)
facilitated sidestepping the mind set of not applying
fracturing to high permeability. The incremental production from only one year of the fracturing program
would have ranked as the 10th largest producing field
in the United States (e.g., Smith and Hannah, 1996),
without including similar results achieved by another
operator in the other half of the field. Another significant aspect of the Prudhoe Bay application is that the
fractures were routinely placed in a relatively small oil
zone above a rising water zone without entering the
water zone (Martins et al., 1992a), which demonstrated that fracturing is a viable, potentially superior
alternative to matrix treatments in high-permeability
formations. This precise fracturing was achieved by
coupling an initial detailed fracture modeling study
with a calibration treatment before each proppant
treatment.
Reservoir Stimulation
Casing
Packed-back
fracture
A5-19
High
permeability
Propped
fracture
Low or
moderate
permeability
A5-20
Reservoir Stimulation
A5-21
A5-22
tifying spurt loss is particularly important for highpermeability formations and is not practically attainable by any other means than after-closure analysis.
The after-closure analyses are presented in Section
9-6, and a method to quantify reservoir parameters
during the closure period is presented in Section 2-8.
These applications from the reservoir behavior of
fracturing complement the 1979 adoption of reservoir
methodologies and achieve a direct merging of fracturing into the classic realm of reservoir testing and
characterization (see Chapters 2 and 12). Reservoir
characterization from a calibration testing sequence
to define fracturing parameters provides the ingredients essential for on-site, economics-based treatment
optimization.