Flowback of fracturing proppant during production is acommon problem. The consequences of this can be extremelyserious. Loss of fracture conductivity can occur due toreduced width, which can be further compounded by partialplugging of the pack by proppant fines. The latter areproduced by non-uniform loading on the proppant withresultant failure and crushing. The produced solids can wreakhavoc with both downhole and surface equipment, erodingchokes and nipples, plugging flow lines and filling separators.In the case of subsea wells, the problems are even greater andcan compromise well security. Since the 1980's, the standardsolution applied for prevention of proppant flow back has beenthe use of curable resin coated proppant. While this approachhas met with some success, it is far from perfect. The use ofRCP's can cause fluid compatibility problems and can interferewith well clean up. Such problems have prompted resinmanufacturers to modify their products and have also openedthe door for the introduction of new technologies. Newerdevelopments have included the use of small fibres to try tobind the proppant pack together or heat-sensitive plastic filmto partially encapsulate clusters of proppant. These materialshave reportedly been used with some success but concernshave been raised with regard to their effect on fractureconductivity, amongst other things.This paper describes the current methods in use andpresents a new system that actually enhances fractureconductivity and minimises embedment and width-loss, whilesimultaneously helping prevent proppant back-production.
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