Process for producing hydrocarbon material from a subterranean formation while employing solids control

Abstract

There is provided a hydrocarbon production process including stimulating a hydrocarbon material-containing reservoir by hydraulic fracturing of the hydrocarbon material-containing reservoir with a treatment material including proppant. The treatment material is injected such that a frac pack is obtained. During production, hydrocarbon material is conducted from the reservoir to the surface via the frac pack. Flow control members are manipulated to enable injection of the treatment material and, subsequently, production of the hydrocarbon material from the reservoir.

1 . A hydrocarbon production process, implemented via a system including a wellbore string disposed within a wellbore extending into a subterranean formation, wherein the wellbore string includes a flow communication station including a material injection station and a material production station, wherein the material production station is disposed downhole relative to the material injection station, wherein the material injection station includes a material injection flow control member for opening and closing a material injection flow communicator that is disposed in flow communication with the subterranean formation via a wellbore space, and the material production station includes a material production flow control member for opening and closing a material production flow communicator that is disposed in flow communication with the subterranean formation via a wellbore space, wherein the material production flow communicator includes a filter medium for preventing oversize particulate material from entering the wellbore string, comprising:
 opening the material injection flow communicator by displacing the material injection flow control member, relative to the material injection flow communicator, with a shifting tool;   while the material injection flow communicator is disposed in the open condition, injecting stimulation material, including proppant that is entrained within a fluid, from the surface and into the subterranean formation, via the wellbore string, the material injection flow communicator, and the wellbore space, such that hydraulic fracturing of a hydrocarbon material-containing reservoir of the subterranean formation is effected;   continuing to inject the stimulation material with effect that a frac pack is obtained within the wellbore space, between the subterranean formation and the material production flow communicator; and   after the frac pack has been obtained:
 suspending the injection of the stimulation material; 
 after the suspending of the injection of the stimulation material, opening the material production flow communicator by displacing the material production flow control member, relative to the material production flow communicator, with a shifting tool; and 
 after the opening of the material production flow communicator, producing hydrocarbon material from the subterranean formation via the frac pack, the material production station and the wellbore string. 
   
     
     
         2 . The process as claimed in  claim 1 ;
 wherein the injection of the stimulation material is effected while the material production flow communicator is disposed in the closed condition.   
     
     
         3 . The process as claimed in  claim 1  or  2 ;
 wherein the injection of the stimulation material is effected while a sealed interface is disposed within the wellbore string, downhole relative to the material injection flow communicator. 
 
     
     
         4 . The process as claimed in claim in any one of  claims 1  to  3 ;
 wherein the sealed interface is disposed uphole relative to the material production flow communicator; 
 and further comprising: 
 after the frac pack has been obtained, and prior to the opening of the material production flow communicator, defeating the sealed interface. 
 
     
     
         5 . The process as claimed in any one of  claims 1  to  4 , further comprising:
 prior to the opening of the material production flow communicator, closing the material injection flow communicator. 
 
     
     
         6 . The process as claimed in any one of  claims 1  to  5 ;
 wherein both of: 
 (i) the displacing of the material injection flow control member, relative to the material injection flow communicator, from the closed position to the open position; and 
 (ii) the displacing of the material production flow control member, relative to the material production flow communicator, from the closed position to the open position; 
 is effected by the same shifting tool. 
 
     
     
         7 . The process as claimed in any one of  claims 1  to  6 ;
 wherein:
 the material injection flow control member includes a sleeve; and 
 the material production flow control member includes a sleeve. 
 
 
     
     
         8 . The process as claimed in any one of  claims 1  to  7 ;
 wherein:
 prior to the opening of the material production flow communicator, the material production flow control member is releasably retained, relative to the wellbore string, in a retained position by a fragible interlocking member; 
 
 and further comprising:
 applying a force, in a downhole direction, wherein, in response to the application of the the downhole-directed force, fracturing of the frangible interlocking member is effected such that release of the material production flow control member, from the retention relative to the wellbore string, is effected. 
 
 
     
     
         9 . The process as claimed in  claim 8 ;
 wherein:
 the downhole-directed force is applied to the material production flow control member; and 
 after the release of the material production flow control member, from the retention relative to the wellbore string, and in response to the application of the downhole-directed force, displacement of the material production flow control member, relative to the material production flow communicator, is effected in a downhole direction; 
   such that, in response to the application of the downhole-directed force:
 (i) the release of the material production flow control member, from the retention relative to the wellbore string, is effected; and 
 (ii) after the release of the material production flow control member from the retention relative to the wellbore string, displacement of the material production flow control member, relative to the material production flow communicator, is effected in a downhole direction; 
   and   such that the opening of the material production flow control member includes the displacement of the material production flow control member, relative to the material production flow communicator, in a downhole direction.   
     
     
         10 . The process as claimed  9 ;
 wherein the distance by which the material production flow control member is displaced, relative to the material production flow communicator, from the retained position, in response to the application of the downhole-directed force, is less than six (6) inches.   
     
     
         11 . The process as claimed  9 ;
 wherein the distance by which the material production flow control member is displaced, relative to the material production flow communicator, from the retained position, in response to the application of the downhole-directed force, is less than three (3) inches.   
     
     
         12 . The process as claimed  9 ;
 wherein the distance by which the material production flow control member is displaced, relative to the material production flow communicator, from the retained position, in response to the application of the downhole-directed force, is less than two (2) inches.   
     
     
         13 . The process as claimed in any one of  claims 10  to  12 ;
 wherein:
 the system further includes a hard stop; 
 the material production flow control member and the hard stop are co-operatively configured such that:
 while the material production flow control member is disposed in the retained position, the hard stop is disposed downhole relative to the flow control member by a distance of less than six inches; and 
 after the material production flow control member has been released from the retention relative to the wellbore string and is being displaced in a downhole direction by the downhole-directed force, the hard stop is disposed for becoming disposed in abutting engagement with the material production flow control member for preventing, or substantially preventing, displacement of the flow control member, relative to the material production flow communicator, in the downhole direction. 
 
 
 
     
     
         14 . The process as claimed in  claim 13 ;
 wherein the displacement of the material production flow control member, relative to the material production flow communicator, in a downhole direction, that is effected in response to the application of the downhole-directed force, is with effect that the material production flow control member becomes disposed in abutting engagement with the hard stop, such that displacement of the material production flow control member, relative to the material production flow communicator, in the downhole direction is prevented, or substantially prevented, by the hard stop.   
     
     
         15 . The process as claimed in any one of  claims 9  to  14 , further comprising:
 after the application of the downhole-directed force that has displaced the material material production flow control member, relative to the material production flow communicator, in a downhole direction, displacing the material production flow control member, relative to the material production flow communicator, in an uphole direction, with effect that the material production flow communicator become disposed in a non-occluded condition; 
 such that the opening of the material production flow control member includes the displacing of the material production flow control member, relative to the material production flow communicator, in an uphole direction. 
 
     
     
         16 . The process as claimed in  claim 15 ;
 wherein, in the non-occluded condition, there is an absence, or substantial absence, of occlusion of any portion of the material production flow communicator by the material production flow control member.   
     
     
         17 . The process as claimed in  claim 16 ;
 wherein a dimension of the material production flow communicator, measured along an axis that is parallel, or substantially parallel, to the central longitudinal axis of the wellbore string, is at least one (1) foot.   
     
     
         18 . The process as claimed in  claim 16 ;
 wherein a dimension of the material production flow communicator, measured along an axis that is parallel, or substantially parallel, to the central longitudinal axis of the wellbore string, is at least three (3) feet.   
     
     
         19 . The process as claimed in  claim 16 ;
 wherein a dimension of the material production flow communicator, measured along an axis that is parallel, or substantially parallel, to the central longitudinal axis of the wellbore string, is at least five (5) feet.   
     
     
         20 . The process as claimed in any one of  claims 15  to  19 ;
 wherein the material production flow communicator and the material production flow control member are co-operatively configured such that the minimum distance, by which the material production flow control member is displaced, relative to the material production flow communicator, in the uphole direction and along an axis that is parallel, or substantially parallel, to the central longitudinal axis of the wellbore string, from the retained position, for effecting disposition of the material production flow communicator in the non-occluded condition, is at least one (1) foot. 
 
     
     
         21 . The process as claimed in  claim 20 ;
 wherein the minimum distance is at least three (3) feet.   
     
     
         22 . The process as claimed in  claim 20 ;
 wherein the minimum distance is at least five (5) feet.   
     
     
         23 . The process as claimed in  claim 14 , further comprising:
 after the application of the downhole-directed force that has displaced the material material production flow control member, relative to the material production flow communicator, in a downhole direction, displacing the material production flow control member, relative to the material production flow communicator, in an uphole direction, with effect that the material production flow communicator become disposed in a non-occluded condition;   such that the opening of the material production flow control member includes the displacing of the material production flow control member, relative to the material production flow communicator, in an uphole direction;   wherein:
 in the non-occluded condition, there is an absence, or substantial absence, of occlusion of any portion of the material production flow communicator by the material production flow control member; and 
 the material production flow communicator and the material production flow control member are co-operatively configured such that the minimum distance, by which the material production flow control member is displaced, relative to the material production flow communicator, in the uphole direction and along an axis that is parallel, or substantially parallel, to the central longitudinal axis of the wellbore string, from, for from the position at which the flow control member is disposed while in abutting engagement with the hard stop, is at least 14 inches. 
   
     
     
         24 . The process as claimed in  claim 23 ;
 wherein the minimum distance is at least 38 inches.   
     
     
         25 . The process as claimed in  claim 23 ;
 wherein the minimum distance is at least 62 inches.   
     
     
         26 . The process as claimed in any one of  claims 23  to  26 ;
 wherein a dimension of the material production flow communicator, measured along an axis that is parallel, or substantially parallel, to the central longitudinal axis of the wellbore string, is at least one (1) foot. 
 
     
     
         27 . The process as claimed in any one of  claims 23  to  26 ;
 wherein a dimension of the material production flow communicator, measured along an axis that is parallel, or substantially parallel, to the central longitudinal axis of the wellbore string, is at least three (3) feet. 
 
     
     
         28 . The process as claimed in any one of  claims 23  to  26 ;
 wherein a dimension of the material production flow communicator, measured along an axis that is parallel, or substantially parallel, to the central longitudinal axis of the wellbore string, is at least five (5) feet. 
 
     
     
         29 . The process as claimed in any one of  claims 15  to  28 ;
 wherein the displacement of the material production flow control member, relative to the material production flow communicator, in the uphole direction is with effect that the entirety, or the substantial entirety, of the material production flow communicator is non-occluded by the material production flow control member. 
 
     
     
         30 . The process as claimed in any one of  claims 8  to  29 ;
 wherein the retained position corresponds to disposition of the material production flow control member in the closed position. 
 
     
     
         31 . A hydrocarbon production process, implemented via a system including a wellbore string disposed within a wellbore extending into a subterranean formation, wherein the wellbore string includes a material injection station and a material production station, wherein the material production station is disposed downhole relative to the material injection station, wherein the material injection station includes a material injection flow controller for modulating a flow communication condition of a material injection flow communicator that is disposed in flow communication with the subterranean formation via a wellbore space, and the material production station includes a material production flow controller for modulating a flow communication condition of a material production flow communicator that is disposed in flow communication with the subterranean formation via a wellbore space, wherein the material production flow communicator includes a filter medium for preventing oversize particulate material from entering the wellbore string, comprising:
 opening the material injection flow communicator by displacing the material injection flow controller relative to the material injection flow communicator;   while the material injection flow communicator is disposed in the open condition, injecting stimulation material, including proppant entrained within a fluid, from the surface and into the subterranean formation, via the wellbore string, the material injection flow communicator, and the wellbore space, such that hydraulic fracturing of a hydrocarbon material-containing reservoir of the subterranean formation is effected;   suspending the injection of the stimulation material;   after the suspending of the injection of the stimulation material, partially opening the material production flow communicator by displacing the material production flow controller relative to the material production flow communicator, such that:
 (i) an uphole-disposed portion of the material production flow communicator is occluded by the material production flow controller; and 
 (ii) flow communication is effected between the subterranean formation and the wellbore string via a downhole-disposed portion of the material production flow communicator, such that reservoir material is conducted from the subterranean formation and into the wellbore string via the downhole-disposed portion of the material production flow communicator in response to a pressure differential between the subterranean formation and the wellbore string, and such that solid particulate material, entrained within the conducted reservoir material, separates from the conducted reservoir material and accumulates within the wellbore space, that is disposed between the subterranean formation and the material production flow communicator, and at least contributes to formation of a solid particulate material-containing filtering medium; 
 wherein the downhole-disposed portion of the material production flow communicator is disposed downhole relative to the uphole-disposed portion of the material production flow communicator; 
   and
 after the formation of a solid particulate material-containing filtering medium, increasing the percentage opening of the material production flow communicator by displacing the material production flow controller relative to the material production flow communicator such that a production mode material production flow communicator is established, with effect that reservoir material is conducted from the subterranean formation and into the wellbore string via the solid particulate material-containing filtering medium and the production mode material production flow communicator. 
   
     
     
         32 . The process as claimed in  claim 31 ;
 wherein the partial opening of the material production flow communicator is with effect that the uphole-disposed portion, of the material production flow communicator that is being occluded by the flow controller, defines at least 50% of the total cross-sectional flow area of the material production flow communicator.   
     
     
         33 . The process as claimed in  claim 31 ;
 wherein the partial opening of the material production flow communicator is with effect that the uphole-disposed portion, of the material production flow communicator that is being occluded by the flow controller, defines at least 75% of the total cross-sectional flow area of the material production flow communicator.   
     
     
         34 . The process as claimed in any one of  claims 31  to  34 ;
 wherein the increasing of the percentage opening of the material production flow communicator is with effect that the material production flow communicator is disposed in the non-occluded condition. 
 
     
     
         35 . The process as claimed in any one of  claims 31  to  34 ;
 wherein solid particulate material-containing filtering medium includes solid particulate material that has accumulated during the injection of stimulation material. 
 
     
     
         36 . The process as claimed in any one of  claims 31  to  35 ;
 wherein the injection of the stimulation material is effected while the material production flow communicator is disposed in the closed condition. 
 
     
     
         37 . The process as claimed in any one of  claims 31  to  36 ;
 wherein the injection of the stimulation material is effected while a sealed interface is disposed within the wellbore string, downhole relative to the material injection flow communicator. 
 
     
     
         38 . The process as claimed in  claim 37 ;
 wherein the sealed interface is disposed uphole relative to the material production flow communicator;   and further comprising:   after the formation of a solid particulate material-containing filtering medium, and prior to the increasing of the percentage opening of the material production flow communicator, defeating the sealed interface.   
     
     
         39 . The process as claimed in any one of  claims 31  to  38 , further comprising:
 prior to the partial opening of the material production flow communicator, closing the material injection flow communicator. 
 
     
     
         40 . The process as claimed in any one of  claims 31  to  39 ;
 wherein:
 the displacing of the material injection flow controller, relative to the material injection flow communicator, is effected by a shifting tool; and 
 the displacing of the material production flow controller, relative to the material injection flow communicator, is effected by a shifting tool. 
 
 
     
     
         41 . The process as claimed in any one of  claims 31  to  39 ;
 wherein both of: 
 (i) the displacing of the material injection flow control member relative to the material injection flow communicator; and 
 (ii) the displacing of the material production flow control member relative to the material production flow communicator; 
 is effected by the same shifting tool. 
 
     
     
         42 . The process as claimed in any one of  claims 31  to  40 ;
 wherein:
 the material injection flow control member includes a sleeve; and 
 the material production flow control member includes a sleeve.