Permanent Downhole Gauges - A4 - eProduction Solutions

Permanent Downhole Monitoring®A Weatherford CompanyeProduction Solutions (eP),a Weatherford Internationalcompany, provides solutionsto increase production andlower lifting costs in green andbrown fields. We deliver agile,well-supported products andservices that foster innovativeoptimizing approaches for flowingwells and all forms of artificiallift. The software, hardwareand completions solutions canstand-alone or integrate with thedownhole gauge product offeringto help you work better, smarterand faster.Give us your unique application . . .and we’ll give you the right tool for the job.We offer a complete range of downhole permanent sensors and gauges toaddress the wide range of well applications found in today’s modern productionenvironments.•••OpticalQuartzSilicon-on-insulator (SOI)Optical sensing systems offer value for hostile well environments, particularly wherewell intervention is costly, if not altogether impossible. Optical sensing technologyis a robust solution when dealing with commingled production from multiple zones,high-temperature/high pressure (HT/HP) and high-rate gas wells. Vibrations (V) fromhigh-rate wells do not affect the performance of the sensors. Optical systems canintegrate pressure and temperature with multiphase flow measurements, distributedtemperature, downhole seismic and remote flow-control capabilities.Quartz and SOI electronic downhole gauge systems offer flexibility while prioritizingoverall well economics. Permanent monitoring of artificial lift applications, reservoirpressure monitoring, free-flowing wells, multi-zone applications and onshore andoffshore platform wells are all typical candidates where temperatures and pressuresare in the moderate to elevated range. Our quartz and electronic gauges have beencontinuously improved, through innovative engineering practices, to increase lifeexpectancy while decreasing infant mortality.© 2006 Weatherford. All rights reserved.

Permanent Downhole MonitoringWeatherford’s Permanent Downhole GaugesOptical Pressure/TemperatureOptical Downhole Flow MeterOptical Distributed Temperature SensingArray Temperature SensingOptical 4D Permanent SeismicElectronic Quartz Gauges UsingHybrid Design Transducer ElectronicsOpticsmPOD 2mPOD 3*ePQGsPODMultiple Point ElectronicSOI-Type Pressure/Temperature GaugeSingle Point ElectronicSOI-Type Pressure/Temperature Gauge*also measures vibrationOur solutions span simple to complex applications, from low producing assetsto wells generating thousands of barrels per day and/or millions of cubic metersper day. Whether you need a single-point pressure/temperature (P/T) instrumentto accentuate pump-off control or the ability to accurately measure temperature,pressure and flow in a HT/HP multizone well with optical sensing, we have the rightsolution.For each unique application, we provide a fit-for-purpose system to fulfill therequirements. The common thread to all our solutions is the wide operatingtemperature range and the engineered-in reliability and accuracy demandedeven in extreme environments. We use only best-in-class components to ensurerepeatable quality for years of continuous service. Weatherford systems andsolutions provide real value in all well phases of both brown and green fields.In addition to downhole gauges, subsurface systems and sensors, we alsooffer robust and flexible instrumentation solutions for the accumulation, display,transmission and storage of acquired data. These surface systems can be standaloneor compatible with legacy SCADA and communication systems. Downholemeasurements can be part of a well or reservoir system or part of a comprehensivefield optimization solution. The combination of downhole measurements withsurface data and control systems enable better long-term management of the well,reservoir and field.© 2006 Weatherford. All rights reserved.

Permanent Downhole MonitoringTypical Applications for Permanent DownholeMonitoringPermanent downhole monitoring provides data that enables better decisions forimproving production operations and reservoir management. Better decisions canaccelerate production and increase ultimate recovery while reducing downtime.Temporary systems for making downhole measurements require well-interventions;but permanent systems remove the need for interventions reducing the relatedcosts plus operational, production, safety and environmental risks associated withinterventions.Choosing the Right ProductThe charts to the right depicttypical production applicationsand the technology suggestedfor each. For a detailed reviewof your particular application andassistance with selecting thebest-suited technology, contact aWeatherford representative.Conventional Well Measurements OpticsQuartzSOIePQG mPOD 2 mPOD 3 sPODHigh-Temperature/High-Pressure u & a a aArtificial Lift F F u u uPressure/Temperature u u u u uDownhole Vibration Monitoring a a a u aCoal Bed Methane a a F F uProduction/Injection Profiling u a a a aWell Startup Monitoring u a a a aDownhole Flow Measurement u a a a aExtended Reservoir MonitoringOpticsQuartzSOIePQG mPOD 2 mPOD 3 sPODZonal Isolation Monitoring u u u u aReservoir Pressure Monitoring & u & & KPressure Transient Analysis u u K K FMeasurement Across the Reservoir u K & & aDistributed Temperature Sensing u a a a aArray/Multipoint Sensing u K & & aSeismic Imaging and Monitoring u a a a aWater and Steam Breakthrough u a a a aLegendu Recommended for this type applicationp Recommended for most applications of this typek Recommended for some applications of this typef Recommended for specific types of this applicationa Not recommended for this application© 2006 Weatherford. All rights reserved.

Permanent Downhole MonitoringPressure Monitoring ApplicationsApplication Description BenefitsWell PerformanceReservoirPressure ControlHistory MatchingTransient WellTestingHydraulicFracturingBottomholePressure DataReal-time access tobottomhole pressureEstablish bottomhole flowingpressure above critical valuewhile adjusting surfacefacilities production orinjection ratesHistorical log of pressuredata during lifetime of theassetHistorical log of bottomholepressure providesopportunity for transientanalysis during plannedor unplanned shut-in anddrawdown of reservoirpressuresReal-time reservoir pressureduring hydraulic fracturingoperationsReal-time access tobottomhole pressure•••••••••••••••••••••••Upper completion performance establishedGravel pack performance establishedMonitoring for fines, scale or wax build-upWellbore hydraulic curves calibrated for optimizing gas liftOptimize production or injection ratesMonitor drawdown to reduce probability of sand productionAvoid long term damage to reservoir, improve recoveryefficiencyExtend life of completionValidation of reservoir modelsUpdate or enhance reservoir understandingUpdate recovery efficiency, estimate of reserves andlifetime of assetTransient analysis without interventionEarly analysis of problem wells without waiting for plannedinterventionFacilitates programming of regular reservoir surveillance toreduce severity or impact of problem wellsEliminate deferred production associated with wellinterventionIdentify fracture initiationOptimize fracture/stimulation durationOptimize surface operations, duration and costsEnhance safety for pressure control operationsDiagnostic pressure data during well intervention, leak-offtests, valve cycling, etc.Enhance safety for pressure control operationsCorrect fluid weights during remedial well operationsSubsurface pressure data for drilling and completion offuture wells© 2006 Weatherford. All rights reserved.

Permanent Downhole MonitoringWeatherford Optical InstallationsOptical P/T sensor–has a rugged glass microstructure featuring two Bragggratings to measure strain associated with pressure and temperature. Thisoptical tool boasts the industry’s highest mechanical shock and vibrationsurvivability. Integration of the single-piece P/T transducer with a simplepressure housing delivers the smallest part-count and highest reliability for a P/Tinstrument. Immeasurable drift means that there are no concerns about absolutepressure and temperature measurement over the life of the field. This sensor israted for environments to 347ºF (175ºC).Optical sensors are widely used with high producing wells where workoversresults in substantial production and revenue loss. Because of their resilientdesign, the sensors resist deterioration and consequently failure over thelife of the well. Optical sensors also have the ability to deliver additionalmeasurements–such as distributed and array temperature sensing, multiphaseflow rates and seismic–on one multifiber cable.250200150100500

Permanent Downhole MonitoringsPOD P/T gauges–are rated to temperatures of 257°F (125°C). The singlepoint P/T SOI-type gauge transmits a square wave, current-pulsed output onthe supply current (same conductor for power and signal). The square wave iscounted and processed to generate the sampled downhole parameters, pressureand temperature. The gauge is fully compensated (calibrated) for increasedaccuracy.This gauge is commonly used with artificial lift applications for low to moderateproduction assets. It provides information that allows operators to understand thechanges occuring downhole.Weatherford Cumulative ElectronicInstallations vs. Failures2500200015001000Accumulative Permanent Gauge CompletionsAccumulative Failures5000199719981999200020012002200320042005*2006*projectedWhy Weatherford Permanent Downhole Monitoring?Options. Rather than offer a single product for all downhole situations, we offer youa selection of fit-for-purpose solutions targeted to specific operational needs.Reliability. Our subsurface gauges and surface control units consistently operate forperiods far exceeding industry standards. A comprehensive series of environmentalstress tests ensure stringent criteria are met for thermal shock, mechanical shockand thermal aging.Experience. Our products and technology have benefited equipment operationand optimized production by limiting downtime on more than 15,000 wells. Wehave more than 25 years of experience with electronic downhole gauges and morethan a decade of experience with optical sensing and intelligent well technologies.We have installed more than 100 optical systems to date, with a track record ofinnovation that includes many “world firsts” and award-winning technology andtools. We have achieved milestones of 1 million ft (305,000 m) of fiber-optic cableand 3 million ft (915,000 m) of optical fiber installed in wells. These achievementsreflect more than one million cumulative in-well operating hours for our opticalsystems. Weatherford has installed over 2000 permanent monitoring systems withelectronic gauges to date, resulting in more than fifty-six million cumulative in-welloperating hours for our electronic monitoring systems.© 2006 Weatherford. All rights reserved.

Permanent Downhole MonitoringAlignmentSubHydrow-IIHydraulicProductionPackerw/HASValveESPAssemblyTubingHangerTR-SCSSVSafety ValveLandingNippleOptical Sensing SystemsOptical systems can provide data for more efficient development and operation ofsimple and complex reservoirs. They offer clear advantages for certain well typesand applications in terms of performance, reliability, cost and ease of installation. Infact, for multi-zone and other challenging well environments, optical systems delivercapabilities that no alternative technology can match.The sensors themselves are all glass to withstand high temperatures, pressuresand vibration. The glass is also immune to interference from local radio or electricaltransmission sources. From a simple P/T optical gauge above-the-packer tohorizontal, multizone sand screen completions, Weatherford provides an integratedoptical architecture for virtually all life-of-asset measurements that you may need.Typical Applications for Optical SystemsHigh Temperature/High PressureOptical sensing systems can withstand temperatures to 347°F (175°C). All theelectronics are located at the surface and are more easily accessible for upgradesand maintenance; high-reliability, passive components remain downhole.Pressure/Temperature ApplicationsIn horizontal completions, P/T gauges are useful for defining drainhole productionefficiency. When coupled with flow-control valves or inflow control devices, thesegauges can ensure uniform production across a long horizontal section.Production and Injection ProfilingOptical distributed temperature sensing (DTS) and array temperature sensing(ATS) systems may allow determination of production and injection profiles acrossthe reservoir sections of horizontal, multilateral and multizone wells.PackersSand Screen Hanger PackerOptical P/TSensor MandrelOptical P/TSensor MandrelDura-Grip HD Sand Screens© 2006 Weatherford. All rights reserved.

Permanent Downhole MonitoringWell Startup MonitoringOptical P/T sensors can be used effectively during well startups, not only tomeasure real-time reservoir pressure, but to manage initial drawdown. Ourproprietary EPS Products software, such as the PanSystem and PanMeshprograms, are used to create inference tests and pressure transient analysis toprovide reservoir boundary information.Downhole Flow MeasurementReal-time downhole flow measurement is critical for optimizing production frommany of today’s complex well designs, including intelligent, multi-zone andmultilateral completions. Data from a downhole flowmeter can be used to reduce oreliminate the need for surface well testing and the resulting operational, safety andenvironmental effects.Optical flowmeters have no borehole restrictions or intrusions into the flow path.They are bidirectional, scalable to any pipe size and feature a control-line bypassfor use in intelligent well systems. These flowmeters can be configured for single-,two- or three-phase flow and are applicable to production and injection wells.Distributed Temperature SensingDTS allows monitoring of the thermal profile of the entire well, giving an indicationof the production or injection profile across the reservoir sections and helpingto identify flow anomalies, such as tubing or casing leaks, thief zones and flowobstructions. DTS has also been useful in determining completion effectivenessand the performance of gas lift valves.PanSystem software is theindustry’s leading well testingprogram. PanSystem softwareincorporates a wide range ofanalytical models to analyze thewellbore, reservoir, and boundarypressure response.Optical P/TSensor MandrelOptical P/TSensor MandrelSneaky DrainBull NosePanMesh software integratesseamlessly with PanSystemsoftware to provide an efficientand accurate numerical welltesting simulator and enablesinterpretations of models beyondthose possible with analyticalapproaches.DTS Termination Sub AssemblySeal Sub© 2006 Weatherford. All rights reserved.

Permanent Downhole MonitoringOptical Subsea ApplicationsIn keeping with the philosophy of providing fit-for-purpose solutions, we offertwo fundamental types of implementations for subsea environments. The firstoption is an all-optical solution that involves eliminating all electronics from theseabed, where access can be difficult and costly. We install dedicated fiberin the umbilicals and cabling to connect the subsea wellhead, along with thein-well sensors, to the surface. The advantage of this implementation is thatthe complex opto-electronic instrumentation is located on the surface (in somecases, tens of kilometers away from the well), where it can be readily accessedfor upgrades or repairs.A second implementation solution requires installing the opto-electronicinstrumentation in the subsea wellhead. This option is used when the requiredfiber or fibers are not available in the umbilical or subsea cabling, and cansupport P/T monitoring systems.Fiber in the umbilical solutions is preferred and is available for all opticalsensing systems. A key enabling component for optical subsea monitoringsystems is the subsea-tree wet connector. Together with our industry partners,we provide wet-mate connector solutions for both vertical and horizontalsubsea trees.The Intelligent Screenssystem combines our opticalsensors and Weatherford wellscreens–two highly effectiveand successful technologies–toenable safe, easy and permanentmonitoring across perforatedintervals and open-hole sectionsin sand-control completions.Subsea opto-electronic instrumentation© 2006 Weatherford. All rights reserved. 11

Permanent Downhole MonitoringTubingRetrievableSCSSVP/T GaugeTubing HangerGas LiftMandrelChemicalInjectionQuartz Gauges (ePQG)The ePQG quartz gauge transmits a binary frequency shift keyed (BFSK) signaltransmission protocol. The transmission scheme allows for multiple ePQGs to bepowered and communicate on the same, single-conductor cable. In addition totransmitting both pressure and temperature data, continuous monitoring of thegauges’ head voltage allows for basic diagnostics of cable integrity during the life ofthe installed equipment.The micro-processor based design allows for monitoring of regulated gauge voltageand overall gauge current for analytical and operative performance monitoring.Because frequency can be measured with greater precision than any otherparameter, the sensor’s frequency output provides a high resolution, accuratepressure measurement.Quartz is a perfectly elastic material, providing sensor stability and repeatability.The quartz resonator has a high Q (quality factor), which means that its vibrationcan be driven with very little electrical power.Typical Applications for Quartz GaugesHigh-Temperature/High-PressureElectronic systems are an economical solution when operators are faced withmoderate to high P/T applications. Systems are rated to 302°F (150°C) to meet thisdemanding environment with exceptional accuracy and resolution.Artificial LiftMeasure pressure and temperature data for automation and analysis needs,including gas lift, progressing cavity pumps (PCP) and more. With permanentmonitoring proactive decisions are facilitated to reduce production downtime.Pressure/Temperature Applications and Reservoir Pressure MonitoringIn horizontal or vertical applications, provision of in-well quartz P/T eliminateswireline intervention or production downtime for pressure surveys.Zonal Isolation Monitoring and Pressure Transient AnalysisThe ePQG provides robust longevity for a variety of applications, from basic landto complex offshore (dry) completions. Communications or commingling of theslightest amount can be detected with the accuracy and resolution of the ePQGquartz gauge.Packer12© 2006 Weatherford. All rights reserved.

Permanent Downhole MonitoringSOI-Type GaugesmPOD² and mPOD³Our mPOD² gauges transmit a proprietary protocol when addressed. Using anaddressable scheme allows multiple digital sensors to communicate and bepowered on the same, single-conductor cable. In addition to transmitting bothpressure and temperature data, continuous monitoring of the sensor’s head voltageallows basic diagnostics of cable integrity throughout the life of the installed system.These gauges are rated to environments of 257°F (125°C). One of the mainapplications of these gauges is measurement of pressure and temperature aboveand below an artificial lift pump. The accuracy of these measurements allows youto identify the problems of underproducing wells.Our mPOD 3 gauges have all the features and technology of the mPOD 2 but incorporatethe measurement of downhole vibration (Grms, frequency (G-force)). This capability isuseful in diagnosing artificial lift applications and free flowing wells. Vibration information,in addition to P/T measurements, gives you yet another factor for determining problemsand potential problems downhole. By measuring the vibration of artificial lift equipment,pumps can be right-sized to eliminate wear from vibrations. Production adjustmentscan reduce operational challenges in the pump before they become severe.sPOD Single-Point SOI GaugeDesigned for permanent installed applications, our sPOD gauges maintain aminimum count of electronic components. The data is collected and processedwith coefficients that are generated from a least mean squared, third-orderpolynomial fit calibration that is performed at Weatherford’s production optimizationmanufacturing and test facility. Calibration and verification testing ensures thatthe gauge adheres to and exceeds the accuracy and resolution specificationdetermined for the design.These gauges are rated to environments of 257°F (125°C). They transmit a squarewave,current-pulsed output on the supply current (same conductor for powerand signal). The square wave is counted and processed to generate the sampleddownhole parameters, pressure and temperature.Typically used for artificial lift applications in low production wells, sPOD gaugesare fully compensated (calibrated) for increased accuracy in low to moderateproduction wells. They provide the information you need to understand the changesoccurring downhole.TubingRetrievableSCSSVCrossoverPackerSplice SubOrientationSubROSS-VSplice SubTubingHangerWX NippleSplice SubGaugeMandrelHCAU-3WX NippleOrientationSubPackerGaugeMandrelSplice SubsPODmPOD 2OrientationSubWX NippleROSS-VOrientationSubWXN NippleBull Nose© 2006 Weatherford. All rights reserved. 13

Permanent Downhole MonitoringSafety ValveP/T GaugeTubingHangerCrossCouplingProtectorsTypical Applications for mPOD and sPOD GaugesArtificial LiftMonitoring a single P/T for pump efficiency or simple POC is a common application.Multiple P/Ts can be used for pump efficiency calculations, optimizing pumpingrates and planning workovers.Pressure/Temperature Applications, Reservoir Pressure Monitoring andPressure Transient AnalysisPermanent electronic systems provide data that reduces the need for wellintervention and the resulting production loss. Operators receive a continual datafeed for the life of the well. Permanent reservoir monitoring provides continuoustransient data without the inconvenience and loss of production experienced duringwell interventions.Vibration (mPOD 3 only)The mPOD 3 system allows determination of in-well vibration caused by flowingor artificially lifted wells. Understanding the severity of the in-well vibrationcharacteristic enables the operator to fine-tune production, eliminating tubing wearor rod breaks.Coal Bed MethaneSimple electronic gauges provide the ability to recover methane at optimum rateswhile maintaining positive well economics. They provide the data needed to facilitateproper drawdown of the fluid column while maintaining pump coverage.Zonal Isolation Monitoring, Measurement Across the Reservoir and ArrayMultipoint SensingThe mPOD 2 and mPOD 3 use a unique addressing communication protocolallowing multiple gauges to be dropped on the same monoconductor, in-well cable.Zonal monitoring provides critical data to the operator to understand productioncontributions from isolated or commingled reservoirs.GaugeMandrelInstallation Accessories and OptionsWe carry a complete line of bare or encapsulated downhole cables, pneumaticcable spooling units, tool boxes, splice assemblies, junction boxes and othertools, accessories and procedures to facilitate installations and well completionsin all environments, satisfying every application requirement. We also employ anexperienced and highly-trained installation team.Packer14© 2006 Weatherford. All rights reserved.

Permanent Downhole MonitoringInstrumentation, Data Interface and CommunicationsOptical and Quartz Gauge InterfaceWeatherford offers a full line of reservoir monitoring systems (RMS) to fit thescale and complexity of your completion projects. There is an RMS surface systemfor interior or non air-conditioned, even harsh environments. These systemsprovide web-enabled accessibility for reading on demand.Our basic RMS provides integrated information to operators from multiple opticaltools. It can operate as a stand-alone data-acquisition, management, display andcommunication system or it can seamlessly interface with legacy SCADA, secureintranets, Internet or communication systems. With considerable local storageavailable, the RMS can hold an extensive amount of high frequency data. Thesystem features a single shared network for Modbus, TCP/IP and OPC.The system supports a simple P/T application to multiple P/T and DTS tools. TheRMS, RMS-WH (wellhead), and RMS-WH-Q (quartz) can monitor up to six optical orelectronic tools.mPOD and sPOD Gauge WSMS InterfaceThe CS7X wellsite management system is an Internet-ready, modular, scalablesystem designed to provide real time process control and monitoring of oil and gasproduction facilities. The advantage of the CS7X well site management system(WSMS) is that it has been designed with built-in applications that minimizereconfiguration requirements. An integral web server supports direct viewing of processdata using off-the-shelf browsers such as Microsoft ® Internet Explorer or Netscape ® .A flash file system supports FTP file transfer of system configuration and HTML files.Internal data Logging and IO capabilities are standard functionality of the WSMS.sPOD Gauge InterfaceA surface interface for the sPOD single-point digital gauge, the ePRO dataprocess system has data storage and pressure-signal output that provides an idealsolution for single well applications. The system can output a pressure controlsignal to variable speed drive controllers to automate artificial lift equipment andbe installed world-wide with no special considerations for venting or heating. TheePRO system offers compact size with ease-of-use. Designed for ruggedness, thesystem can be pole mounted or building enclosed.Control room RMS applicationmodel.Microsoft and Netscape are trademarks of their respective owners.Well head/well site RMS modelfor desert or open environment.Single well ePRO interface unit for the sPOD gauge.© 2006 Weatherford. All rights reserved. 15

CALGARYABERDEENHOUSTONDUBAICARACASSINGAPOREWeatherford locationsRegional officesEverything for the life cycle of your well . . . wherever you are.Drilling, evaluation, completion, production and intervention. Weatherford’sglobal network of more than 30,000 people, operating from 730 servicebases, 87 manufacturing facilities and 13 technology development andtraining facilities, in more than 100 countries, ensures in-country expertiseand logistical support. You also have the reassurance of fit-for-purposesolutions, best practices, best services and best products.515 Post Oak Blvd., Suite 600Houston, Texas 77027Tel: 713-693-4000www.weatherford.comWeatherford products and services are subject to the Company’sstandard terms and conditions, available on request or atwww.weatherford.com. For more information contact an authorizedWeatherford representative. Unless noted otherwise, trademarks andservice marks herein are the property of Weatherford. Specificationsare subject to change without notice. Weatherford sells its products andservices in accordance with the terms and conditions set forth in theapplicable contract between Weatherford and the client.© 2006 Weatherford. All rights reserved. Brochure 4449.00