Introducing a New Dissolvable Abrasive Perforating Material to Enhance Fracturing Efficiency
Authors: Samuel Mathew , Kharrat Wassim , Hamdi Abdullah , Rajab Mohammed , Samuel Elsamma 
Published: September 2024

Departure from explosive-based perforating methodology, coiled tubing (CT) abrasive jetting offers a valuable alternative for perforating. This technique employs fluids containing abrasive material, which are jetted at high pressure through a nozzle, creating a clean passage connecting the wellbore to the reservoir without causing perforation damage. Sand is the preferred abrasive material in the traditional methods as it causes significantly less damage to CT and jetting tools compared to more abrasive artificial solids like bauxite or ceramics. However, the use of sand as the perforating medium necessitates a cleanout operation, which demands the need of large volumes of viscosified fluids stable at high temperature.

In this study, the perforating performance of a novel Dissolvable Abrasive Perforating Particulate (DAPP) composite material is compared with that of conventional 100 mesh and 20/40 mesh silica sand. The effectiveness of the new abrasive material is compared with traditional solids in terms of the time required to punch through a 4.5-inch casing, the punch outer diameter (OD) of the casing, the punch OD of the cement block, and the penetration depth within the cement block observed during the yard test.

This material offers exceptional performance, delivering penetration and hole size comparable to conventional sand-based abrasives. This product creates cleaner holes compared to traditional methods, ensuring optimal wellbore connectivity. This innovative solution presents several benefits including: (1) Operational time savings by eliminating sand cleanout, reducing total operation time, (2) Pipe life preservation by eliminating the reciprocation of CT, (3) Fluid savings through the elimination of cleanout stages, resulting in substantial savings of water and gel system, (4) Stuck pipe risk elimination by enabling dissolution of solid with solvent for wells where sand cleaning from the hole is complex due to high temperature, high deviation and low annular velocity, and (5) Applicable in both Carbonate and Sandstone formations as the abrasive material is soluble in non-HCl systems. This material is highly recommended for deviated and horizontal wells, particularly in low porosity and damaged reservoirs. Due to its perforating efficiency and solubility, DAPP can also be used to simplify the "perf and plug" operations in multistage fracturing applications.

This new abrasive system presents a compelling case for its adoption in the oil and gas industry, offering enhanced perforation efficiency, operational savings, and reduced environmental impact. Despite being polymerized with less than 1% of the composite material, this abrasive material exhibits remarkable mechanical strength and toughness. The unique lamellar microarchitecture of the material provides a lightweight structure with toughness several times greater than its base material. The unique properties and performance of this material have the potential to revolutionize perforation operations, improving wellbore connectivity and optimization of complex industry practices.