Expandable Completion - Weatherford International

Expandable Completion SystemsProviding the organizational capabilities, well-screentechnology understanding, system reliability andinstallation experience to effectively address yoursand control challenges.High ProductivityEffective IsolationSolving your sand control challenges.

Expandable Completion SystemsWeatherford:The Expandable Completion Experts Often Imitated, Never DuplicatedToday's expandable system providers are not all created equal.Why? Because while each provider offers systems that expandsteel downhole, the similarities end there.Weatherford has been accelerating theimplementation of all expandabletechnologies, related tools andaccessories since the mid-1990s.Weatherford International Ltd.Weatherford has been a leader in expandable completiontechnologies since the mid 1990s. From the beginning we havefocused on designing, developing, installing and continuouslyimproving expandable technology that overcomes conventionalcompletion design limitations. Along the way we've created aunique and far-reaching knowledge, engineering, manufacturingand distribution infrastructure that cannot be duplicated by anyother expandable completion provider.In short, we now have the organizational capabilities, well-screentechnology understanding, system reliability and installationexperience to effectively address your sand-control challenges.Weatherford International Ltd.(NYSE:WFT) is the fourth largestdiversified upstream oilfield servicecompany in the world, providingindustry-leading technologiesthrough a worldwide infrastructureof 18,000 employees in 108countries. Weatherford’s productsand services span the drilling,completion, production andintervention cycles of oil andnatural gas.A key strategy for Weatherford isthe development and deploymentof production-enablingtechnologies that convert reservesto revenue. These technologiesrange from enabling ones, such asexpandable systems, to upgradesof our classic product lines, suchas tubular running services andcementation systems.To learn more about Weatherford’sfull capabilities, visitweatherford.com.®The simple and reliable ESS sand control technique was the stepping stone forWeatherford’s expandable completion system offering.2© 2005-2008 Weatherford. All rights reserved.

Expandable Completion SystemsThe result is a modular expandable completion system that can bedesigned to address your specific well challenges, ultimatelyhelping you maximize reservoir productivity and reserves recoverywhile minimizing risk and cost. It is an expandable completionsystem you can't get from any other company but Weatherford,The Expandable Completion Experts . Our pioneering expandabletechnologies include:®Expandable Sand Screens (ESS )Weatherford's proven ESS system has been changing the face ofsand control for more than five years, improving well productivityand significantly reducing costs compared to a gravel pack. Oursystem has been especially successful in long, single-zonereservoir sections. The ESS section is expanded compliantlyagainst the wellbore, eliminating the annular space and providingborehole support and sand exclusion, thus removing the need toplace gravel for filtration of formation sand. The system has beenrun in more than 500 installations around the world.Typically, well costs have been cut by20 percent or more, and productivityincreased by up to 70 percent withESS systems.Expandable Solid Tubular TechnologyWeatherford pioneered the development of compliant rotaryexpansion of solid tubulars, facilitating the downhole expansion ofsolid pipes to contact casing wall or wellbore with zero annulus.®The MetalSkin family of products uses this proprietary technologyto provide unique solutions for a number of applications fromcasing repair to isolation of troublesome formations during drilling.On securing a license from Shell in 2002, Weatherford gainedaccess to fixed-cone solid expandable technology. Since then wehave developed a range of products that are installed asintermediate drilling liners to help reduce the telescoping effectassociated with conventional well construction.Weatherford has developed a range ofsolid expandable technologies thatreduce the costs typically associatedwith conventional well construction.© 2005-2008 Weatherford. All rights reserved.3

Expandable Completion SystemsNext-Generation Expandable Completion SystemsThe drive for maximum well productivity compels engineers toattempt to complete oil and gas wells openhole. One of the mainchallenges of openhole completions is the ability to provideeffective zonal isolation. Weatherford's next-generation®expandable completion system evolves and integrates ESS®slotted and MetalSkin solid expandable technology to deliver ahigh-productivity openhole reservoir completion with cased-holeisolation functionality.EXR Liner HangerEnables one-tripinstallation of theexpandablecompletion systemBlank PipeUnexpanded casing in thestring enables integrationwith selective and intelligentcompletionsESS SectionCompliantly expanded for maximumborehole support and sand filtrationEZI SectionSolid expandable technologyprovides effective isolationbetween zones4© 2005-2008 Weatherford. All rights reserved.

Expandable Completion SystemsAnd there are other valuable benefits. By eliminating the need forcementing and perforating, our expandable completion systemcan reduce well construction costs; the efficiency of single-tripinstallation saves rig time; and the openhole completion increasesoil and gas recovery and reduces formation damage.The modular, single-trip expandable completion system can bedesigned for almost unlimited combinations of components thatinclude the following:®ESS sections selectively expand to control the transfer ofreservoir solids to the wellbore, maximize productivity, optimizereliability and increase operational efficiency.®MetalSkin expandable zonal isolation (EZI) compliantexpandedsolid tubulars provide positive zonal isolation whilemaximizing ID to provide better well access for futureinterventions.The slotted expandable completion liner (ECL), expandedagainst the formation wall to eliminate the requirement forperforating, is applicable where downhole sand control is notrequired.Primary Benefitsof ExpandableCompletion SystemsOpenholeproductivity withcased-holefunctionalityUnparalleledflexibility incompletion designNatural extensionof proven ESStechnologySections of blank pipe also can remain unexpanded between theESS, EZI and ECL components, providing conventionalwellbore geometries for setting selective and intelligentcompletions and truly delivering unparalleledflexibility in completion design.© 2005-2008 Weatherford. All rights reserved.5

Expandable Completion SystemsOrganizational CapabilitiesUnrivaled R&D, Engineering and Manufacturing Facilities®Petroline WellSystems Ltd. manufactured the first prototype ESSsystem in 1997.After aquiring Petroline in 1999, Weatherford made a significantinvestment in manufacturing and technical service supportsystems and infrastructure, all of which have helped acceleratethe development of the technology.Our expandable-specificcapabilities are supported byWeatherford's worldwide R&Dnetwork. The network includes twoof the industry's largest R&D,testing and training facilities,located in Houston and Aberdeen.Specialized Engineering KnowledgeWeatherford has assembled a highly talented team of completionspecialists whose depth of expertise and breadth of disciplinesrange from mechanical, petroleum and reservoir engineering tohighly specialized metallurgy and rock mechanics.Custom-Build Manufacturing FacilityWeatherford manufactures the full spectrum of expandableproducts at our own purpose-built facility in Aberdeen, Scotland.Our advanced manufacturing methods and equipment include theworld's only four-head laser cutting machine and the world'slargest abrasive water-jet equipment. We also use custom-built,automated slotting, weave wrapping and welding machines tomanufacture ESS systems to our exacting specifications.Automated ESSConstruction ProcessAutomated High-PressureWater Jet SlottingControlled Bench Testing of ExpandablesWeatherford’s unique expansion test and qualification rig has acomplete data-acquisition suite and a power capability equal tothat of a full-scale drilling rig. Data acquisition is networked to ourdesign office to give dedicated design engineers immediateaccess to all test information.We conduct tests to model actual pending installation operationsfor specific clients and then analyze the data to formalize designlimits and develop best deployment practices. Weatherford alsouses this physical testing to validate state-of-the-art, threedimensional,nonlinear finite element analysis (FEA). FEAdeepens our understanding of the plastic deformation process andis fundamental to the development of next-generation systems.6© 2005-2008 Weatherford. All rights reserved.

Expandable Completion SystemsExpandable Technology UnderstandingBetter Candidate Selection Process, Knowledge of SuccessfulOperating EnvelopesExcellentCased hole wellOpen hole wellopen hole gas well®With more than 500 ESS systems now installed in a variety ofoperating conditions in numerous locations worldwide, we'veamassed a significant body of knowledge and gained anunparalleled understanding of how to apply the technology.We also conducted a detailed study on more than 70 of ourinstallations. This study has helped us further improve expandablecandidate selection procedures, determine successful operatingenvelopes, and scope out the next generation of expandablecompletion systems, which are now available. Highlights of whatwe've learned:Expandable completion systems work best in openholeapplications, where they have a track record for improvingproductivity and controlling sand production. We comparedthe results of ESS systems in openhole versus cased-holeapplications and found that the performance of this technologyin both openhole oil and gas wells ranged from good toexcellent in the areas of productivity, sand control and ease ofimplementation. In cased-hole applications, installed ESSsystems ranked lower.These findings were not surprising. ESS technology was notoriginally designed for cased-hole applications; however, as aresult of this knowledge, we significantly tightened our casedholeESS application guidelines and incorporated most of thecurrent design features of ESS technology into the nextgenerationsystem.Average performance rating per critrionGoodModeratePoorVery poorESS Performance per Criteron perWell Type# of skins30252015105InitialinvestmentOperating costProductionperformanceSand controlperformanceEase ofimplementationEase of useduring operationLong termreliabilityExpecteddowntimeRisk of reducedproduction/shut-inPossibilities forzonal isolation# Cone OH SkinImpact onwater cut# Compliant OH SkinCompliant Expansion and IncreasedProductivityImpact ongas cut0>-1 > 0 > 1 > 2 > 3 > 4 > 5 > 6 > 7 > 8 > 9Skin Value (range)Compliant expansion and the large ID of the ESS systemstabilize the borehole and significantly contribute toimproved production performance. Various third-party studiesconfirm that eliminating the annulus through compliantexpansion improves sand control. Our own studies furtherproved this finding. We compared skin caused by wellboredamage in 70 wells where we've collected this type of data. Theaverage skin for the compliantly expanded ESS system was0.3, while systems expanded with by non-compliant methodsexhibited an average skin of 2.3.© 2005-2008 Weatherford. All rights reserved.7

Expandable Completion SystemsDrawdown (PSI)051015202530354045500 500 1,000 1,500 2,000 2,500Distance from heel of well (ft)ESS 7.50-in. IDOHGP 4.89-in. IDOHGP 4.00-in. ID3,000 3,500Large ID and optimal inflow: For wellsflowing at the same rate, thedrawdown profile for the ESS systemis much flatter than those for the twohorizontal openhole gravel packoptions. The flatter drawdown profilegives the ESS system a much higherproductivity index and a flatter inflowprofile. The flatter inflow profile has thepotential to slow the influx of water intothe well and to improve the ultimaterecovery of oil.PI (stb/day/PSI)140012001000800600400200PI (stb/day/PSI)Heel/toe inflow0 0ESS 7.50-in. ID OHGP 4.89-in. ID OHGP 4.00-in. IDCompletion option654321Heel inflow/toe inflow®Likewise, the large ID of the ESS system has an intrinsicallylow friction-induced flowing pressure reduction. This advantagehelps increase productivity, reduce water or gas coning andimprove overall recovery in the reservoir. A smaller-IDcompletion, on the other hand, induces preferential inflow at theheel of the well, which causes water or gas to be drawn in at theheel, reducing oil flow and ultimately recovery.Using the coarsest weave possible for a particular sandreduces the possibility of plugging by mud or the mud filtercake. We've conducted lab tests measuring pressure and sandretention build-up on ESS weaves with various reservoir sandssince the beginning of 2002. Results show a good correlationbetween the largest particles in a distribution and the retentionperformance of the weave.Consequently, part of our in-house specialists' filter mediaselection process includes evaluation of particle-sizeinformation, by sieving or laser diffraction, and sand retention,mud-flowback and full-scale screen testing beforerecommendation of an appropriate weave.Metallurgy affects performance in terms of expansion,collapse and tensile bond. We typically conduct anassessment of well corrosivity and provide specific materialrecommendations for all ESS applications. For production wells,we assess the fluid, temperature and pressure data todetermine the partial pressures of acid gases and estimate thepotential in situ pH of produced waters. We then assess thein situ pH, pH2S and chloride content and temperature levelsto evaluate the risk of localized corrosion or environmentalcracking.As a result, we usually recommend an austenitic stainless steel,which offers high ductility, strain-hardening rate and fracturetoughness for the base pipe and shroud sections. Thisspecification is well suited to moderately corrosive CO2-bearingreservoirs. For connectors, we use super duplex stainlesssteels, which have a minimum yield strength more than doublethat of the austenitic base pipe. Weatherford can upgrade thesematerials as needed for specific applications.Lab Tests for Weave Filtration Media8© 2005-2008 Weatherford. All rights reserved.

Expandable Completion SystemsDocumented Reliability withWell-Engineered ProductsCompliant Expansion Design Is Key®The ESS SystemDesigned for reliability, the ESS system is a combination of fouroverlapping rectangular sheets of Petroweave metal weavefilters attached to a slotted expandable base pipe and encasedwithin a protective metal shroud. This construction provides amechanical, permeable sand filter that supports the originalwellbore. Compliant expansion minimizes the annulus andreduces near-wellbore stress-induced damage, significantlyreducing the likelihood of fines production and migration.In addition, the unique wellbore-compliant design, combined withthe in situ properties of the rocks that the ESS system supports,enables the ESS system to withstand large changes in formationstresses caused by drawdown and depletion.Proven collapse resistance. An independent third-party jointindustry project, started in 2001, studied the boreholestabilization effects of the ESS system in large-scale pressurevessel tests. The ESS system was expanded in situ either to becompliant or to leave an annulus of known dimensions. The testswere conducted in a variety of weak rock and unconsolidatedsands to investigate the effects of an annulus, breakouts and theinterface between weak and strong materials. Very largesimulated-depletion and drawdown-induced stress changes(up to 10,000 PSI) were applied, with no loss of ESS systemstability or sand retention integrity.Differential Pressure (PSI)4035302520151020/40 sinteredmetal screens200-micronsintered weave20/40 pre-packedscreens5200-micronESS membrane0 0 5 10 15 20Time (min)Sand Screen Blockage ComparisonStress (PSI x 1,000)252015105Hoop stressRadial stress0 0 10 20 30 40 50Depth into Formation (in.)Stress Arch Development in theFormationWellbore stability model. We've used the results of the tests toqualify an expandables wellbore stability model, with which wescreen all applications for collapse. A limit of 20 percent reductionin ID in application screening ensures that the deformation of theESS system never results in an operating ID less than theminimum ID of the completion or a loss of sand retentionintegration.Normalized ESS ID (in.)1.000.980.960.940.92ModelpredictionsESS deformation0.90 0 5,000 10,000 15,000Effective Stress Changes (PSI)Experimental ESS Deformation andModel Predictions for Large Changesin Effective Stress© 2005-2008 Weatherford. All rights reserved.9

Expandable Completion SystemsExpandable Tubular SystemsWeatherford has acquired considerable experience in predictingthe effects of expansion on tubular performance. Tubularexpansion is a deformation process that naturally effects changesin material properties concurrent with changes in dimensions. Asdifferent materials respond differently to the introduction of plasticstrain, the ability to use material data in conjunction withdimensional changes in various orientations has been key todeveloping predictive capabilities for such properties as tensilestrength, toughness, and burst and collapse resistance. Suchpredictive capabilities enhance the reliability of new systemdesigns and have been reinforced by extensive product testing.The ultimate goal of solid tubulartechnology is reduction of thetelescopic nature of well design andconstruction.Parametric finite element analysismodels are calibrated with physicaltesting and are used to predictexpansion parameters and steernext-generation designs.®Weatherford’s MetalSkin technology has been usedextensively to address wellbore isolation challenges. Unique,proprietary compliant expansion technology enables atubular-to-wellbore fit, eliminating annular flow and resistingdifferential pressures.10© 2005-2008 Weatherford. All rights reserved.

Expandable Completion SystemsProven Expandables Installation ExperienceInstalling More Expandables Each Year Than Any Other Company®Since its first commercial application of an ESS system, inJanuary 1999, Weatherford has broken a number of newexpandable technology barriers and set several industry records.The following timeline captures the highlights.1993:1995:1999:Shell and Petroline sign slotted research and developmentagreement.An installation in west Texas marks the first commercial®application of slotted alternative borehole liner (ABL )tubulars.Weatherford acquires Petroline and commerciallylaunches the ESS system.An installation in Nigeria marks the first horizontal ESSapplication.2000:2001:2002:2003:2004:2005:2007:Weatherford begins developing solid expandables.A record-setting ABL installation takes place in Oman.Weatherford's installation of an ESS system in the North Searepresents the longest ESS installation to date.An ESS installation in Asia marks the first multizoneapplication.Shell and Weatherford sign new global license agreementcovering slotted and solid expandable technology.In Asia, Weatherford deploys its solid expandable liner hangersystem for the first time.®In California, Weatherford deploys its MetalSkin cased-holeremediation system for the first time.A job in the Niger Delta marks the 225th ESS installation.More than 300 ESS systems have been installed around theworld, including the Gulf of Mexico, South America, Asia, NorthSea, Middle East, Azerbaijan, Africa and Australia.The world's first 7-in. expandable isolation system is successfullyinstalled in a trial well in south Texas.More than 500 ESS systems installed around the world.Weatherford has expanded more than36 miles of its ESS product in locationsaround the world.© 2005-2008 Weatherford. All rights reserved.11

Solving your sand control challenges.Weatherford products and services are subject to the Company’s standard terms andconditions, available on request or at weatherford.com. For more information contact anauthorized Weatherford representative. Unless noted otherwise, trademarks and servicemarks herein are the property of Weatherford. ESS and ABL are registered trademarks in the515 Post Oak Blvd., Suite 600Houston, Texas 77027 USAUnited Kingdom. Specifications are subject to change without notice. Weatherford sells itsproducts and services in accordance with the terms and conditions set forth in the applicablecontract between Weatherford and the client.Tel: 713-693-4000weatherford.com © 2005-2008. Weatherford. All rights reserved. 1332.01