SPE-174075-MS

Frac Sleeve Designed for Multi-Zone Cemented Laterals

Steve Chauffe, Nigel Pence, and Michael Harris, Tools Team Oil

Copyright 2015, Society of Petroleum Engineers

This paper was prepared for presentation at the SPE Western Regional Meeting held in Garden Grove, California, USA, 27–30 April 2015.

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Abstract
A ball-activated sliding sleeve design for multistage cemented lateral completions has been developed that
allows multiple frac sleeves to be opened using the same diameter ball, significantly increasing the total
number of sleeves available in the completion design. This paper discusses the sleeve design, the
challenges associated with cemented laterals, the results of initial field installations, and the ramifications
for completion design and execution.
Ball-activated sleeves were introduced to overcome limitations of plug and perf designs and facilitate
longer and more complex completions. As these completions have evolved, the technology has reached
inherent design limitations. This is especially true in cemented lateral completions. These installations
require a series of incrementally smaller balls and ball seats that reduce wellbore ID and ultimately limit
the total number of sleeves that can be used in the completion.
To further extend lateral length and accommodate the cemented laterals, a sliding sleeve device has
been developed that allows multiple sliding sleeve valves to be opened with the same size ball and seat.
The sliding sleeve design allows up to 90 individual sleeves to be opened as a single point of entry
completion without dropping a ball diameter smaller than 4.00-in. in 5.500-in. casing, or a 3.25-in. ball
in 4.500-in. casing. This increases wellbore ID over the length of the completion, and increases the total
number of sleeves or sleeve clusters that can be employed in the completion design. The higher number
of available sleeves affects the completion design, whether it uses single sleeve per stage or clusters of
sleeves. In addition, lateral length of the completion is not constrained by the number of sleeves or the
reach of coiled tubing.
Cemented installations in the US Marcellus, Utica Shale, and Spraberry plays have enabled single-
point-of-entry stimulations that optimize hydraulic fracturing pressure and provide a focused frac. In some
applications, this has reduced pump rates and surface horsepower requirements by as much as 50% and
also reduced the overall frac time. Experience also indicates these completions reduce water requirements
by minimizing over-flushing of the formation. These cemented installations illustrate the potential of
continued changes in completion designs and the viability of longer laterals.
This paper is the first published examination of field performance in the initial installations of the
sliding sleeve technology. Field results and data from sleeves installed in Marcellus, Utica Shale, and
Spraberry completions are presented. Based on performance in these applications, the paper reviews
2 SPE-174075-MS

completion design considerations facilitated by the ability to install larger numbers of sliding sleeves over
longer cemented laterals.
Introduction
The majority of cased hole horizontal wells in unconventional reservoirs require multi-stage stimulations.
This calls for some form of isolation between the frac stages. (Blevins and Frazier, 2011) There are three
primary methods of achieving this isolation: cemented plug-and-perf (P&P), openhole completions with
ball activated sliding sleeves, and cemented cased hole completions with ball activated sliding sleeves.
The development of these methods describes a continued evolution aimed at improving efficiency and
extending the capabilities of multi-stage stimulation.
Cemented Plug-and-Perf Completions
Cemented P&P methods have been used for decades and are the oldest and most frequently used
multistage stimulation method. Once production casing or liner is cemented in place, the plug and perf
process isolates the stage by pumping a bridge plug down hole on wireline along with perforating guns.
The plug is set, the zone is perforated, and the tools are pulled out of the hole. The zone is stimulated with
the plug diverting fluid into the formation. This process is repeated until all zones have been stimulated.
To flow back the well after the treatment, coiled tubing is used to mill out the plugs.
P&P operations are typically a slow, expensive process with inherent technological limitations in
longer, more complex completions. Perforation clusters present frac delivery and production performance
issues, and the pump-down technique requires over displacement that can consist of several hundred
barrels of fluid. (Phelan et al. 2013) The plugs are also problematic due to wellbore restrictions,
over-torque of casing collars, dogleg severity, and casing buckling. (Blevins and Frazier, 2011)
The use of coiled tubing to drill out the plugs presents another set of limitations based mechanical
capabilities and added cost. As wells become deeper and more deviated, much of the strength and capacity
of coiled tubing to do work downhole is lost to frictional drag in the wellbore. (Kilgore, 1992) In deep
wells, small diameter tubing must be used to accommodate reel capacity and road restrictions, which
limits pumping rates because of pressure and velocity. (McNeil et al. 2011) Using coiled tubing for
drillout in very long laterals can be complex and require an aggressively tapered string and the use of
friction reducers and vibration tools to apply enough WOB to mill out all the completion plugs. (Asafa
et al. 2014) Coiled tubing drillout of composite or cast iron bridge plugs and isolation sleeves often results
in drilling problems such as poor fluid efficiency and hole cleaning issues, lost circulation, stuck pipe,
lost-in-hole tools, and parted pipes. (Liston and Lynn, 2014.)
Openhole Sliding Sleeve Completions
Open-hole multi-stage completions using sliding sleeve technology were introduced in or around 2001 to
enable selective zonal stimulation, enhance production management. The continuous frac operations
facilitated by sliding sleeves improved efficiency and eliminated the downtime associated with P&P
operations. Typical sliding sleeve completions are accomplished in a fraction of the time required to
complete a plug-and-perf operation, and the reduced pump time lowers the overall cost of the completion.
(Snyder and Seale, 2012) (Bozeman and Degner, 2009)
This process first runs the production casing or liner and openhole multistage assembly into the well.
The first frac sleeve (typically pressure activated) is opened and the treatment is pumped. When the stage
is completed, the next sleeve activation ball is dropped. This continues until the continuous pumping cycle
is complete. Millout via coiled tubing is sometimes required to flow back the well, although this has been
reduced by the advent of dissolving or decaying activation balls.
The ball provides two key functions -–– opening the sliding sleeve via hydraulic force and sealing to
allow the treatment to be pumped. Activation of multiple sliding sleeves requires incrementally sized balls
SPE-174075-MS 3

and seats, which ultimately limit the number of sleeves that can be used. This was not an issue in openhole
completion where a single sleeve can effectively stimulate a 200 to 300 ft openhole zone, and there are
typically 20 or fewer stages.

Cemented Sliding Sleeve Completions

Cemented completions using sliding sleeves were installed to further advance the efficiency and capa-
bilities of multistage completions. The approach was first used in the Eagle Ford shale where laterals were
cemented to ensure fracture stage isolation. (Furguson et al. 2012) Traditional frac sleeves have several
limitations in a cemented lateral: the number of sleeves that can be run is insufficient, the inherent design
is not suited for a cemented lateral, and the restricted internal diameters cause problems with cement wiper
plugs and remedial operations.
Conventional sliding sleeve technology with incremental ball seats reduces wellbore ID with each
installed sleeve. These constraints in turn limit the practical length of the lateral and the completion
designs achievable with a limited number of sleeves. The total number of sleeves that can be effectively
installed is less than 40 in a typical 4.500-in. completion. The majority of cemented laterals require a
minimum of 60 sleeves. The limitation is due to the use of incremental ball seats.
Traditional frac sleeves are not designed to mitigate the risks associated with a cemented environment.
These frac sleeves have moving parts that are exposed to the cement and cement wiper plug. A poor
cement wiper job results in residual cement that is left in the wellbore that causes sleeves to not function
as designed.
The small internal diameters (ID) of the ball seats also cause problems in a cemented lateral. Unlike
openhole completions, a cement wiper plug is required to pass through these ball seats. As the ball seats
become smaller and smaller, the wiping efficiency of the cement wiper plug also decreases dramatically.
The inability to effectively wipe the casing results in residual cement being left in the casing. The small
ID of the traditional frac sleeve also prohibits remedial coiled tubing operations. It is common for coiled
tubing to be utilized to perform various remedial operations such as tubing conveyed perforating and clean
out runs.
The solution to the limitations of the tradition frac sleeve in a cemented environment is a sleeve
specifically designed for the cemented environment. The sliding sleeve design allows up to 90 individual
sleeves to be opened as a single-point-of-entry completion without dropping a ball diameter smaller than
4.00-in. in 5.500-in. casing, or a 3.25-in. ball in 4.500-in. casing. This increases wellbore ID over the
length of the completion, and increases the total number of sleeves or sleeve clusters than can be employed
in the completion design. The large ID’s of the sleeve allow for the use of a heavy-duty cement wiper plug
and also accommodate the remedial use of coiled tubing operations when required. The three-layer design
of the tool eliminates the risk associated with residual cement being left in the casing string.
The ability to install and effectively complete a 90-stage sleeve system, allows for single point of entry
completions. A single-point-of-entry completion is illustrated in Fig 1. In this comparison, a two-stage X
3 cluster P&P completion can be completed as a six-stage single-point-of-entry completion with less
horsepower and time. With up to 90 available sleeves, single-point-of-entry completion is possible for
entire laterals.
4 SPE-174075-MS

Figure 1—Plug and perf completion (left) and single-point-of-entry with cemented sliding sleeve (right)

Sliding Sleeve Concept

The need for reliability in a cemented environment, longer laterals, more complex, tailored completions,
and greater flexibility, led to a major redesign of sliding sleeve technology specifically for cemented
multi-zone completions. The criteria for the design was:
●Reliability in cemented wellbores
●Increase the number of frac sleeve without reducing ID
●Limit or eliminate CT drillout requirements
Three-Layer Protection
Key to the concept was risk mitigation in a cemented environment. A three-layer design used in the sliding
sleeve and an associated toe valve locates moving parts between an outer and inner sleeve to protect the
mechanism from the cement slurry as well as frac sand while providing a full-bore ID. The protected
sleeve ensures full opening and access to the formation. Drilling rig installation is enhanced by the ability
to rotate while running in the hole. The large, smooth ID of the tool allows a heavy-duty wiper plug to
be used for cement displacement to ensure a cleaner wellbore and a better cement job.
Ball Activated System
To address completion efficiency and design concerns, the sleeve uses patented technology that enables
a 90-stage capability in single entry designs using nine different balls sizes no smaller than 4.00 in 5.50-in
casing completions. A 90-stage sleeve completion utilizes 90 individual sleeves and 90 balls. The system
is designed for nine sets of 10, meaning each set of 10 sleeves uses the same size ball. There are nine ball
sizes available.
Within the sets of 10, each sleeve is preset and assembled in the completion string for a specific cycle
of balls. The first sleeve is set to allow nine balls to pass before activation; the next sleeve allows eight
balls to pass. In this manner, the first ball cycles through the first nine sleeves until it reaches final sleeve,
SPE-174075-MS 5

at which point the ball seats to open the frac ports and divert the stimulation treatment. This process
repeats itself up the wellbore until each of the 10 sleeves has been activated and stimulated. Upon
completion of the sequence, the next set of 10 slightly larger balls is dropped. Nine ball sizes allow for
90 independent single-point-of-entry stimulations.
The large ID ball seats eliminate the pressure drop and flow rate restrictions exhibited by conventional
incremental ball seats. With 90 individual sleeves to design with, the total stage count can be increased
without having to increase the stage length.
Sliding Sleeve Design
Sliding sleeve operation in a cemented environment presents different considerations than an openhole
application. Because the ID of the device is exposed to the cement slurry, as well as wiper plugs and the
frac treatment, an important design factor was the need to keep moving parts and critical components out
of the flow path. Optimizing the flow paths was important to tool clean up after the cement was placed
and a large ID was needed to accommodate heavy-duty cementing plugs.
The core objective in the design was to address the growing number of stages in long horizontal laterals
by enabling the maximum number of sleeves to be used in the completion. Various means of maximizing
sleeve numbers have been tried but the mechanical solutions are complex. These have included assemblies
of control valves and tethered control lines as well as very long mechanical systems.
A sliding sleeve design employing a series of large ball sizes to open ten sleeves per ball size was
developed to significantly increase the number of available sleeves. The key to the technology is a linear
indexing mechanism that is preset to count a specific number of balls before opening the sleeve. This
allows individual sleeves or series of sleeves to be opened. (Fig 2)

Figure 2—Sliding sleeve design employs a linear indexing mechanism that is preset to count a specific number of balls before opening
the sleeve.

The indexing system is based on common body lock ring technology that consists of an indexing sleeve
and inner mandrel. As each ball passes through the tool, the mechanical indexer changes one position. For
example, if the indexer is set at the number ten position, the first ball moves it to the number nine position;
the second ball moves it to position eight. When the 10th ball is dropped, the indexing sleeve is moved
to the final position, and the ball seats in a frac C-ring to open the sleeve and divert the treatment.
The system achieves a good deal of design flexibility and risk mitigation. For example, a smaller
completion with 20 sleeves can be done with two sets of 10 sleeves, or four sets of five sleeves.
Frac Ball Development
Frac ball design is a central aspect of the sliding sleeve technology. Key to this was eliminating the
potential of a costly drillout by developing dissolvable balls for the large ID seats. While 3 ¾¾-in.
6 SPE-174075-MS

diameter balls are typically the largest size made, the smallest ball in the sliding sleeve system is 4 in. for
the 5.500-in. completion.
In addition to manufacturing, the larger balls affect performance characteristics. The volume of the ball
doubles as the size increases and the ball takes longer to dissolve. The ball also travels differently in the
pipe. Compared to smaller conventional balls that travel more easily with the flow, a larger, heaver ball
tends to roll, which slows travel time. Stresses on the tool and ball are also increased, which lead to
increases in the surface area of the ball and seat.

System Testing
A series of test were performed to develop and qualify the sliding sleeve technology. Torque testing was
conducted to determine the ability of the tools to withstand installation, which can involve rotation of the
assembly. Flow loops were used to test impact levels and how the tool and ball perform together. Flow
loop tests were also done to establish how cement plugs move through the tools. Pressure testing was done
on ball and seat components to ensure the appropriate surface contact area, strength and operating
pressures.

Sliding Sleeve Operation

During the hydraulic fracturing job, sets of up to ten balls are dropped to achieve a continuous pressure
pumping process. This contributes to a much faster treatment compared to P&P because the downtime
associated with wireline use is eliminated.
The initial step is to establish communication with the formation at the toe so that fluid can be displaced
to open the first sleeve. In a common P&P application, the toe shoe is perforated using tubing conveyed
tools and fractured to establish a pump rate sufficient to enable wire line perforating guns to be pumped
down the lateral. The toe may be also be used as the first stage but it is not mandatory.
In the sliding sleeve application, a specialized toe sleeve based on the same three-layer sleeve design
provides an initial injection point. The sleeve allows performance of a high-pressure casing test, and is
hydraulically opened using rupture disks. Rates are typically 40 to 50 bpm versus 80 to 90 bpm in a
plug-in perf job.
Once the designed frac rate is established the ball for the first frac sleeve is dropped at the full rate.
There’s no slow down and the ball is pumped almost the entire length of the lateral at approximately 40
bpm. In comparison, most wireline guns are pumped at about 15 bpm.
The ball is pumped at this rate through all the larger uphole sleeve sets. Approximately 30 bbl ahead
of the top sleeve in the designated set, the rate is slowed to between 5 and 10 bpm, depending on the size
of the ball. As the ball is pumped through this set of sleeves it hits and cycles each sleeve.
When the ball reaches its designated sleeve in the set, it lands on the frac seat to produce a slightly
higher pressure-signature as the sleeve is opening. A much larger pressure increase follows as the virgin
formation is exposed. This can be seen in Figures 4 and 5.
SPE-174075-MS 7

Figure 3—Only a 50 bbl water spacer is pumped as a flush

Figure 4 —Six stages pumped in less than 10 hours with continuous fracing process
8 SPE-174075-MS

Figure 5—Point “““A””” indicates ball action with following pressure higher than preceding pressure

With the sleeve fully open, the treatment follows the planned schedule. When the stage is concluded
a 50-100 bbl spacer is pumped at full rate and the next size ball is dropped to initiate the indexing and
opening of the sleeve up hole. This process continues with each stage and set of sleeves. Tables 1 and 2
compare the frac schedule of a P&P completion to a sliding sleeve completion. The flush and treated water
requirments for the sleeve completion is significanty less than that of the P&P completion.

Table 1—Pump schedule for plug and perf

SPE-174075-MS 9

Table 2—Pump schedule for sliding sleeve

Tables 1 and 2 show pumping schedules for P&P and sliding sleeve applications. While the order of
the frac delivery remains the same, P&P is pumped as a single stage while the sliding sleeve treatment
is pumped in increments.

Case Studies
Recent installations of the sliding sleeve in the US Marcellus, Utica Shale, and the Permian’s Spraberry,
have enabled single-point-of-entry stimulations that reduced pump rates and surface horsepower require-
ments by as much as 50% compared to plug and perf completions. Continuous fracturing operations
achieved with the system greatly reduced completion times and contributed to a savings of more than
$500,000 USD per well.
An 11 well data set, including wells in the US Marcellus, Utica, and Spraberry shale is presented in
this paper. Within the two data sets, there were three primary field applications. Table 3 is the installation
data set. All the wells in the set were 5.500 ft cemented laterals, ranging from a lateral length of 3,203
to 9,670 ft. Table 4 is the stimulation data set for the 11 wells. The average frac rate for these wells ranged
from 30 to 51 bpm. The average frac pressure ranged from 3,477 to 7,861 psi.

Table 3—Installation Data Set

10 SPE-174075-MS

Table 4 —Stimulation Data Set

First Application
Job numbers 1 through 4 represent the first application. Within this application, the objective was for the
operator to complete the entire lateral with sleeves. This offered the operator the opportunity to prove the
effectiveness of the entire system across the entire lateral, further enabling him to compare the overall
results to comparable offset P&P wells.
The total sleeve count for these wells ranged from 36 to 45, covering lateral lengths of 3,203 to 4,480
ft. According to information obtained from the operator, the wells were completed in less than half the
time as their comparable offset P&P wells. The continuous frac operations resulted in substantial
timesavings. The frac time from ball drop to ball drop ranged from 1-1/2 to 2 hours on average.
In addition to the timesavings, the average frac rate was less than half that of the comparable offsets.
The operator was able to stimulate the entire lateral in less time, with less horsepower, and put away close
to 100% of the sand as noted in Table 2.

Second Application
Job numbers 7 through 11 represent the second application, which involved extended reach laterals.
Historically, the operator was inefficient in completing the laterals beyond 6,000 ft. In this application, the
operator installed sleeves in the lower 3-4,000 ft of the laterals. This type of application is often referred
to as a hybrid completion. Similar to the first application, these hybrid completions allowed the operator
to stimulate with less horsepower and time, increasing the overall efficiency. Table 5 and 6 compare
horsepower consumption for job number 8. Table 5 illustrates the single-point-of-entry sleeves, while
Table 6 illustrates the P&P portion of the completion. An average 4,005 hp was needed to complete sleeve
stages 1 to 39 while an average 9,681 hp was was used to complete P&P stages 40 to 56. The reduction
of horsepower and time allowed for a more cost effective and efficient completion of these extended reach
laterals.
SPE-174075-MS 11

Table 5—
12 SPE-174075-MS

Table 6 —

Third Application
In the third application, which is represented by job numbers 5 and 6, the operator installed a minimal
number of sleeves in the lower 1,000 to 2,000 ft of the lateral. This was done to prove that the sleeves
worked mechanically and stimulation could be done at 50% of the normal horsepower and rate. As noted
in Table 4, these two wells were stimulated at rates of 30 and 51 bpm, respectively.
As can be seen in Table 4, a total 325 stages were stimulated with the cemented frac sleeve system.
The frac rates varied from 30 to 51 bpm. The average treating pressures ranged from 3,477 to 7,861
psi.
Figure 4 illustrates stages 14-19 on a Marcellus frac. In this case, six stages were completed in less than
10 hours with the continuous fracing operation offered by the ball activated frac sleeves. The ball seating
on the seat is indicated as point (a) on the figure.
Figure 5 illustrates the ball action on a sleeve more closely. The ball action is noted as point (a) on the
figure. As the rate is held constant, the pressure after the ball action is higher than the pressure before the
ball action. This is an indication that they were injecting into a new zone.
Conclusions
Cemented completions using the sliding sleeve technology have shown the mechanical functionality of the
system and some of economic and design capabilities. This was achieved in various applications,
including extended reach laterals; complete well bore installations; and hybrid systems using the sleeves
in only the lower portion of the lateral. More than 500 sleeves have been successfully installed.
These applications have shown that the ball-activated sliding sleeve design for multi-zone cemented
lateral completions successfully addresses a number of key factors needed to enhance completion
effectiveness and efficiency, including:
● With large ID ball seats, a 90-stage system can be designed with 90 sleeves using one sleeve per
stage. The 90 independent sleeves accommodate cemented laterals in excess of 10,000 ft.
● The sleeves enable single-point-of-entry stimulation that directs hydraulic fracturing pressure
through a single sleeve instead of distributing energy across multiple clusters of perforations.
● Single-point-of-entry stimulation improves efficiency. The focused stimulation results in a more
effective frac job by specifically placing the frac through a single sleeve. Individually stimulating
each isolated sleeve greatly reduces pump rates and surface horsepower requirements.
SPE-174075-MS 13

● Surface horsepower requirements have been cut up to 50% and costs per well have been
dramatically reduced. The system allows rates of just 40-50 bpm compared to standard 100-bpm
frac job using plug and perf methods.
● Less horsepower on location reduces the wellsite footprint and logistical support.
● Overall frac time and water requirements are lowered because stimulating through ball-activated
frac sleeves is a continuous operation, which also minimizes over-flushing the formation. Each
subsequent zone is typically stimulated with less than 50 bbls of over flush. Balls are dropped for
subsequent zones at full rate from surface as the final sand stage is being pumped into the previous
zone. This efficiency eliminates the downtime associated with plug and perf operations.
● In contrast with plug and perf methods, the system enhances safety with no requirements for perf
guns on location
● The system eliminates the water lines and cranes required for pump down in plug and perf
operations.

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