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Depending on conditions, fraced wells can require millions of gallons of water. Getting that water into a site, especially if it’s remote, can prove expensive and challenging. SEI Industries Ltd.’s FRAC Tank is a pillow-style water storage tank that’s easy to set up and can be used immediately with minimal site preparation required. The tanks are lightweight, fully collapsible and can be rolled up easily and moved to a new location. Twelve tanks can be transported on one semi-truck, saving up to 96% on transportation costs compared to steel tanks. One collapsible tank can store as much as 1,200 bbl. In less than 60 minutes, using a manifold system, multiple tanks can be set up to provide whatever volume of storage is required. The tank can be acquired in half the time it takes to get a steel tank. To stand up to frequent relocations and punishing outdoor conditions, the technology’s proprietary industrial fabric is a high-strength, high-abrasion-resistant material that is also chemically-resistant and colored in high-visibility safety orange. The tank is also more cold-resistant than other materials (to -50°C). It features a thicker and denser coating and seams that are all radio-frequency welded (no hot air, wedge welding or gluing). Multiple fill/drain ports are provided on the side of every tank for convenient connection to existing frac water systems, providing flowrates up to 10,000 lpm. For additional durability, heavy-duty abrasion patches protect the tank around these fill/drain ports.
Sound control systems reduces fracing noise by 15-20 dBA
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Noise levels generated from fracing operations are some of the highest generated by drilling and production operations, typically exceeding 100 dBA. They can exceed 80 dBA at 250 ft from the equipment. For logistical reasons, it is difficult to have effective sound-control systems in place prior to the set-up of fracing units and associated piping. To solve the quick deployment and removal issue, Behrens and Associates Environmental Noise Control has developed numerous sound-control systems to block and absorb fracing noise, including a portable STC-32-rated, sound-control panel system. The portable fracing barrier/absorber system is comprised of 8-ft-wide by 12-ft-high free-standing panels with a highly absorbent sound/barrier composite material shroud. The portable panels can be installed in place by two technicians after the fracing equipment is in place. Reversible diagonal supports connect to free-standing base supports to provide a stable support structure that can be set up and removed in minutes, while providing 15 to 20 dBA sound reduction.
Resin-coated proppant enhances oil production
The Oilfield Technology Group (OTG) of Momentive Specialty Chemicals Inc. has introduced a new resin-coated proppant. Selection of the right proppant is critical to the success of fracturing treatments, because oil’s increased viscosity requires higher proppant pack permeability, compared to dry gas. Momentive’s new OilPlus proppant is an advanced, curable resin-coated fracturing sand available in 20/40, 30/50 and 40/70 mesh sizes. The proppant is specifically designed for fracturing treatments in oil- and liquid-rich reservoirs. It increases the relative permeability to oil in the proppant pack, resulting in higher oil production compared to conventional proppants. In addition to improving oil production, OilPlus delivers all of the benefits expected of a stress-bondable, resin-coated proppant.
Software puts sharper scientific focus on shale reservoir parameters
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In many cases, the maximum potential of shale gas plays is not realized, because of a one-size-fits-all attitude concerning drilling and fracture stimulation activities. Because rocks are heterogeneous, particularly in shale plays, a more scientific approach is required to reveal each reservoir’s story, including its depositional environment, organic content, physical properties and potential for oil and gas. This challenge prompted Weatherford to develop the Fracology program to augment operator efforts. The program combines the company’s scientific evaluation offerings, technologies and in-field experience, such that each well’s fracturing program is designed, developed and evaluated to ensure optimal economic productivity. The software helps put a sharper scientific focus on the various physical, geological and geochemical parameters of a shale reservoir, even those that have been historically neglected. This helps the fracture stimulation to yield the best possible outcome in terms of production and field life.
Increasing visibility propels advances in frac fluid chemicals
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Calls for making the constituents of frac fluid chemistries more visible are challenging companies to develop new high-performance frac fluid chemistries that satisfy regulatory environmental mandates and also help operators comply with requirements at specific wellsites. Champion Technologies recently introduced a new scale inhibitor and a new biocide that provide high levels of performance in numerous shales, coupled with much-improved environmental attributes. The new scale inhibitor, Gyptron T-475, blends partially neutralized specialty phosphonates with cross-linked gel system frac fluids, used to boost carrying capacity in many shale plays. It prevents deposition of all common mineral scales by inhibiting and distorting crystal growth, even in the presence of as much as 200 ppm of iron. The chemistry can be winterized to 40°F and is compatible in high-TDS brines. At the wellsite, the inhibitor can be pumped at any time, at recommended dosage rates of 500 to 1,000 ppm. One of the new biocides, Bactron K-31W, is an all-purpose, non-foaming, aqueous glutaraldehyde solution that controls aerobic and anaerobic bacteria in fresh water, sea water and most brines during drilling, workover or completion operations. Developed to be cost-effective in cold climates, the product can be introduced by batch application or continuous injection into water-handling systems, or down the annulus of water-injection or water-supply wells or production wells.
Logging-while-tripping evaluation technique
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Horizontal openhole well logs optimize hydraulic fracturing programs in laterally drilled resource plays by allowing accurate planning and placement of fracture intervals. A comprehensive logging suite provides formation evaluation that makes orders of magnitude more accurate logs, rather than the rudimentary gamma ray and strip logs normally used for evaluating horizontal legs. Rather than pumping blindly into pre-set intervals, logs ensure expensive fracturing horsepower is not wasted in non-productive formations—or worse—applied to environmentally sensitive zones. Datalog’s Logging While Tripping (LWT) is a patented formation evaluation technique in which full-suite, openhole logs are acquired in a method that is more cost-effective, while using less rig time and having fewer inherent risks than wireline, drill pipe-conveyed, or logging-while-drilling methods. LWT allows open hole logs to be acquired in horizontal and hostile hole conditions, where logging was previously impossible or considered uneconomic.
20,000-psi pump increases barrel rates
AXON Energy Products has introduced its HD-2500 pump, adding its HD-500, HD-7000 and HD-1500 pumping technology line. This new offering is a 2,500-hp pump utilizing an optional uprated 3-throw or 5-throw crank with 10-in. displacement. With an increased rod load of 250,000 lb, this rugged pump can realize pressures up to 20,000 psi while delivering higher barrel rates. The company has optimized the materials and manufacturing processes in the HD-2500, assuring the end user of reliable performance in the most rigorous applications. The pump is available in more configurations than any other in its class, enabling you to maximize performance for your application.
High-pressure nitrogen, air booster saves space offshore
The Atlas Copco Hurricane M-41/1000 high-pressure nitrogen and air booster has a small footprint for installation on drilling rigs, as well as mobile drilling platforms. It is available in flexible volumetric capacities. The booster also offers several options for the unit’s prime mover, including a hydraulic motor, PTO/belt drive, and the option of a diesel engine or electric motor. The M-41/1000 is equipped with the features of the new B 41/1000, including 350-psi maximum suction pressure at 1,000-psi discharge pressure. The maximum capacity of this booster module is 2,440 scfm. It features forklift pockets in the base frame, a remotely-mounted control panel, and a digital temperature scanner. The company’s wide range of boosters-—600 to 1,200 psi at 1,400 to 2,500 cfm for single-stage, and 1,200-to-5,000-psi at 500 to 4,500 cfm for multi-stage—enables users to select a solution for every application.
Expandable solid-steel liners maximize outflow performance
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Enventure has developed a suite of three expandable, solid-steel liner products that help ensure successful hydraulic fracturing of a well. The products, known collectively as FracSET, are designed to maximize production, restore well integrity for operations and production, and maximize reserves. Maximizing production is accomplished by using the MaxFrac expandable solid-steel liner to tie back to 51/2-in. or 7-in. casing to maximize lateral ID for optimal fracturing, maximum outflow performance, and ease of re-entry. It is also used to customize frac interval spacing for frac-stage isolation by using solid-expandable and swellable elastomer technologies. The liner system maximizes reserves by providing mechanical isolation of perforations and frac stages for optimizing refracturing, to stimulate new reserves and re-open fracture networks. The entirely expandable product is suited for moderate pressures (to 8,000 psi differential) and temperatures (to 200 °F) in 51/2-in. and 7-in.base casing. The partially-expandable ReFrac system is suited for HPHT conditions (to 10,000 psi differential and 400° F) in 41/2-in. and 51/2-in. base casing. Restoring well integrity for fracturing operations and production is achieved by using the FracSET Repair expandable solid-steel liner, which employs single-joint lengths (up to 60 ft) to isolate casing splits, parted casing, failed frac-port sleeves and perforations.
Experts provide life-cycle water management solutions
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Now more than ever, water is integral to the success of oil and gas operations. As water requirements for hydraulic fracturing increase, source water limitations, infrastructure-related development, fluid handling and the complexity of treating and disposing of produced water all become greater challenges. Select Energy Services’ Fluidity experts provide comprehensive water management solutions capable of lowering costs for approval for expenditure (AFE) and lease operating. From water sourcing and transfer to reuse and disposal, the program offers cost efficient, reliable and environmentally friendly management solutions to every phase of drilling and completion operations. Through the Fluidity division, operators have access to an experienced team of hydrologists, chemists, project development professionals and PhDs. They combine the expertise of Select Energy Services’ WaterOne and WellOne divisions to engineer an all-inclusive water solution at every phase of the water cycle.
Intelligent wireless system monitors fracing downhole
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Tubel Energy has developed a wireless system to monitor pressure, temperature and fluid identification in the wellbore before, during and after fracing the horizontal section of a well. The Intelligent Frac Monitoring System is deployed permanently in the wellbore with the frac pipe string. Up to 256 monitoring systems can be deployed in a single horizontal section. One system can be deployed in the entrance of the horizontal section to monitor all fracs. Multiple monitoring systems can be deployed to monitor individual zones. The technology’s ultra-low power consumption allows for operation in the wellbore for an average five years after the frac is completed. The wireless communications capability eliminates the need to deploy cables in the wellbore for data transfer. The system can collect data as fast as one sample per second. This monitoring can be used to collect a frac’s pressure build-up in the reservoir, as well as the pressure drop once the frac is achieved. The system will indicate that the frac was performed properly and that no over-frac was done that could damage the formation. A second pressure gauge can be placed outside of the system to monitor annulus pressure for zone leaks, reservoir monitoring and cross-zones fluid communications. A new fluid identification sensor package monitors water production, allowing the operator to determine the zones that are producing water in the horizontal section.
Multistage fracturing system for 60 stages downhole
Packers Plus Energy Services has released its QuickFRAC technology, which is capable of fracturing 60 stages downhole while only pumping 15 treatments at surface. By taking a single pumping treatment on surface and precisely directing it into 2 to 5 stages downhole. Using limited entry diversion techniques and our proprietary technology, the system allows operators to fracture several isolated stages at one time through a process known as batch fracturing. This configuration creates multiple, individually isolated stages within a single treatment zone.
Frac isolation system promotes unlimited stages, stage spacing
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NCS Energy Services’ Multistage Unlimited frac isolation system combines a coiled tubing-deployed tool assembly with mechanically-shifted sliding sleeves to perform multi-stage frac completions without perforating guns, pumpdown plugs, or sleeve-actuating balls. The system permits virtually unlimited stages and stage spacing. Multi-stage sliding sleeves are run and cemented as part of the casing string at planned frac initiation points. During completion, the tool assembly is run to the toe on coiled tubing. At each stage, a resettable bridge plug seals and grips the inner barrel of the sliding sleeve, isolating the target formation and allowing coiled tubing weight and annular pressure to shift the sleeve, to open the frac ports. The frac is pumped down either the coiled tubing/casing annulus or the coiled tubing (low-rate fracs). After the frac, pulling the coiled tubing opens the equalizing valve and unsets the bridge plug, and the assembly is moved to the next sleeve. Time between fracs is only about five minutes. With a circulation path to the frac zone via the coiled tubing, the system offers significant advantages over other multi-stage methods. Frac pressure at the formation can be monitored via the coiled tubing deadleg. Pump rates, pressure and sand loading can be adjusted to control frac dimensions and improve frac results. Fluids and sand can be circulated to the target zone before fracturing. Less fluid is lost to the formation, compared with bullheading fluids down the casing. Overall water savings can be as high as 50%. Sandouts are quickly removed with reverse circulation, permitting aggressive sand concentrations and reducing nonproductive time.
Manifold system fits wide range of pad configurations, well spacing
As operators started to frac multiple wells, they recognized the risk, cost, environmental and safety impact of setting up to frac wells on location. Responding to these concerns, and the need for a multiple well frac system, Robbins & Myer has introduced its T3 Frac Manifold Optimization System (FMOS) and flowback trees. The system allows producers to safely extract natural gas and oil from shale formations and has been modularized to accommodate a wide range of pad configurations and well spacing. The unique design of this full-bore system allows continuous operations that are started and completed more rapidly, safely and economically. FMOS is powered by the company’s T3 HPT valves, which contains metal-to-metal seals and are specifically designed for high pressures and highly abrasive service in frac applications. This technology minimizes frac sand bypass and is used for the entire flow path of the frac tree.
Straddle system handles multiple-set operations
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The TAM PosiFrac Straddle System is a tool assembly that can be used for a wide array of applications, such as inflating casing annulus packers, acidizing, fracturing, flow testing, washing perforations, pressure testing and more. The system is designed for multiple-set operations and meeting various needs, such as larger borehole ID, horizontal applications or special testing programs. It can be deployed on a jointed pipe or coiled tubing. The system is functional in both cased-hole and open-hole conditions. There are two types of lock-set mechanisms available. They include rotation lock, or set-down weight lock systems. The system’s standard configuration is rated for a maximum working pressure of 5,000 psi and a maximum working temperature of 300°F. Unique features include two separate sealing element packers, allowing for space-out between the packers to accommodate specific well and/or treating interval requirements. The elements, which inflate simultaneously, are designed and manufactured for resistance to corrosive fluids. Benefits include the ability to retain acid in the string through the use of the TAM Fluid Control Valve while moving between intervals in the wellbore. Treatment and testing of over 100 intervals has been achieved in a single deployment of the system. The system’s multi-set capability includes setting within open perforations, and selective treating of intervals from 3 ft and longer.
Multi-well manifold increases pumping efficiency
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Supreme Services has introduced its Single Pad Multi-well Manifold (SPMW), which offers time-saving, safe operations while delivering pumping efficiencies when stimulating multiple wells on a single pad during fracing. The manifold is a fully hydraulic, remotely operated, stimulation manifold that can safely isolate each well while allowing simultaneous operations. The firm has been successful running wireline tools, pumping down perforating guns and plugs, and performing various flowback operations, all while the next well is being stimulated. The manifold is versatile and can be used on pads with 2-6 wells, all while maintaining pump rates up to 100 bbl/min. Custom modifications for a larger quantity of pad wells are readily available. The manifold has an offline assembly that saves frac time and expense and, to maximize safety performance, the technology is built with fully hydraulic actuation, allowing for remote operations. The tool permits continuous pumping on a multi-well stimulation, and it has a compact footprint for tight locations.
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