SPE Tech Talk: Advancing Automation in Plug and Perf Completions

Adam Dyess discusses Automation in perforating and Hunting’s ControlFire Perf+ https://huntingplc.com/products-servi... If we look back at the past 15 years, the unconventional completion sector has seen tremendous growth in daily stage capacity and operational efficiencies. This is primarily driven by processes and product innovation in the plug-and-perf space, which includes both Wireline and Frack operations. Twenty-plus stages per day is the new norm in several basins throughout North America. If you were to visit any multi-well pad, you can see how various technologies have driven efficiencies and safety by eliminating human error and removing personnel from hazardous zones. Here are a few examples: Automated Wireline lubricator to Wellhead connection: Eliminates the need for personnel to climb and manually connect a lubricator stack in challenging conditions. Sof Frack operations: Involves multiple Frack Fleet and Wireline units working simultaneously on a well pad, revolutionizing the plug-and-perf process. Automated valve Control Systems: Enables digital remote and seamless well-to-well valve control for Frack operations, removing personnel from high-pressure, high-risk zones. Modular Perforating systems: Represent 90% of Perforating guns run in unconventional Wells today, mitigating human error failure points in the field. Despite these advancements, there are still constraints in the overall plug-and-perf process. Labor force issues, including shortages, high turnover rates, and inexperience, have led to stagnant operational efficiencies. The industry is challenged to address these variabilities inherent in manual processes by advancing automation. In terms of variability in the manual plug-and-perf process, very little has changed inside the Wireline unit where several manual activities take place. The Wireline technician is responsible for tasks such as controlling the winch, communicating with the pump truck during the pump down, and manually handling the shooting panel and switches during the Perforating process. These manual processes are prone to human mistakes, leading to misfires or misruns and subsequent downtime. To address these challenges, a software-driven shooting power supply has been introduced. This integrated system automates the entire Perforating process, allowing the technician to focus on monitoring operations rather than handling equipment manually. The system logs and annotates Perforating data, eliminating manual shot sheet confirmation. This step-change technology aims to improve reliability, safety, and operational efficiency. In terms of Frack operations, automation is already abundant, but there is potential for seamless integration with Wireline operations. Collaboration between automated Frack valve controllers and Perforating systems could lead to 24-hour pumping operations without waiting on each other. When asked about potential concerns with automation, safety remains a key focus. However, the argument is made that automating processes can reduce safety incidents associated with human error and misruns. Field results from the automated Perforating panels show successful implementation with zero off-depth perforations. The feedback emphasizes the ability of technicians to concentrate on monitoring operations, resulting in increased efficiency. The primary goal is to remove human interaction inside the Wireline unit, allowing technicians to focus on operations rather than high-stress multitasking. The long-term potential of automation includes envisioning full plug-and-perf automation, collaboration between stakeholders, and near-maximum capacity utilization. Regarding concerns about automation progress being isolated to individual operations, it is acknowledged that discussions and collaboration among operating companies, service companies, and product companies are crucial for advancing automation. Safety concerns related to explosives are addressed by highlighting that most safety incidents occur after a misrun, emphasizing the interdependence of reliability and safety. Automation is seen as a means to reduce safety incidents caused by human error. In conclusion, the automated Perforating system is positioned as a significant step change in the industry, addressing challenges in manual processes and aiming to improve efficiency, safety, and reliability. The ongoing deployment and feedback from the field indicate positive results and the potential for further advancements in automation.