Real-Time Detection of Stage Isolation Failures: A Field Case Study of Multistage Hydraulic Fracturing Using Automated Pressure Analysis

Abstract This paper presents a detailed field case study demonstrating the application of an automated, real-time stage isolation detection system in multistage hydraulic fracturing. The motivation, background, methodology, etc. described in an earlier work (Khan et al. 2025), demonstrates the integration of multiple pressure-based diagnostic criteria with a multi-criteria decision framework. The criteria include ball seat signature evaluation, ISIP and falloff comparison, average pad pumping pressures, water hammer frequency analysis, etc. In this case study, the workflow was deployed in high-rate acid fracturing in a carbonate multi-stage horizontal well. The completion is an openhole liner with isolation packers and fracturing sleeves. The automated system demonstrated the capability to continuously process surface pressure and rate data during treatment, rapidly identifying abnormalities through pressure criteria, indicative of plug failure or interstage communication. Several isolation loss events were detected, verified against domain expertise for post-job diagnostics, and linked to operational or mechanical causes such as premature plug erosion and ball seating anomalies. The system's ability to provide actionable results potentially allows real-time operational adjustments, including pump schedule modifications and proactive intervention planning, minimizing treatment inefficiency and potential production losses. Compared to conventional manual interpretation methods, this approach has potential to reduce decision latency, enhance diagnostic accuracy through ensemble criteria evaluation, and provide consistent, standardized assessments across all treated stages.