Production Tubing Frac Pack: An Unconventional Multi-Zone Design with Significant Cost Savings

Abstract The conventional process of frac packing that was initiated in the early 1990s and revolutionized the industry is well documented in the literature (Meese, et. al., 1994, and Mullen, et. al., 1994). Frac packing provided sand control as well as stimulation in unconsolidated reservoirs, and it has played a key role in enhancing productivity and adding reserves to many wells. The results of frac packing in unconsolidated reservoirs have been so positive, and its acceptance so widespread, that today it is considered standard practice though operators have customized numerous variations of frac packing for specific types of applications. For all the completion processes for frac packing that have been developed to date, one common factor is that rig assist is usually required throughout the entire process, including the phase of fracing the well. Additionally, multizone stack packing completion systems have evolved so that it is common practice to stack completions to economize the high cost of rig service that is involved with intervention (Brannon, et. al, 1991, and Bennett, et. al, 1996). This paper describes an innovative and more economical multi-zone frac packing design known as production tubing frac packing (PTFP), which was developed in 2009 in the Gulf of Mexico. The new design combines the steps of perforating, completion setting, and frac packing into a single trip. PTFP is in the initial phase of a learning curve but has already proven to be more economical and potentially to have a similar impact on the industry as both frac packing and stack packing zones. With PTFP, much of the completion phase is performed through the production tubing after the rig assist has been demobilized, with the biggest savings realized during the rigless frac phase. This paper will cover all phases of the PTFP completion technique and will discuss three case histories.