Optimum Upper-Completion System - Weatherford International

Discover the Optimum upper-completion systemOptimaxsurfacecontrolledsubsurfacesafetyvalveWhen the stakes are high,count on Weatherford to deliver.From the high pressures and high temperatures encountered indeepwater to the corrosive conditions of natural gas storage wells,extreme environments can adversely affect completion equipment,undermine safety and necessitate costly workovers.Drawing on more than three decades of cased-hole completionexperience, we developed the Optimum upper-completion system tomitigate the elevated risk, and potentially expensive consequences, ofperformance failure in such harsh environments.OptiPkr removableproductionpackerLeveraging advanced design featuresThe Optimum upper-completion system features premium componentsdesigned to withstand extremities and to work in tandem with one another.Interventionless completion design. Our system incorporates thegroundbreaking radio-frequency identification (RFID) operated settingmodule that uses radio transmitters and receivers to control packersetting, as well as the opening and closing of sleeves, which reducescost and enhances safety.Modular system. From modular packers and safety valves to flowcontroldevices, each component works in-sync to provide the maximumresults. In addition, we offer several deployment and setting methods,customizable metallurgies and elastomers, and pressure and temperaturevariations—all ensuring that the design is custom-built for your wellbore.OptiSetvalveUniset ®flowcontrolOptiSleeveslidingsleeve2 © 2011-2012 Weatherford. All rights reserved.OptiBarrierisolationvalve

Optimum Upper-Completion SystemWeatherford has two of the largestresearch‐and‐development (R&D),testing and training facilities in theindustry. Based in Houston, Texas,USA, our Technology & TrainingCenter houses the world’s mostadvanced safety-valve engineeringlab and three hot cells that simulatedownhole conditions. Our Aberdeenfacility is Europe’s foremost research,testing and development center foroffshore well services. This facilityincludes two fully operational drillingrigs and test boreholes.© 2011-2012 Weatherford. All rights reserved.5

Value-added expertiseBacked by Weatherford’s strong commitment to internal trainingand research and development, we align our service performanceto your business drivers. Whether the objective is safety,economics, operational efficiency or all of the above, our globalteam of completion specialists is well equipped to support yourcompletion operations.Highly trained personnel. Our efforts to provide you with valueaddedcompletion expertise begin with hiring talented engineersand support personnel, but they do not end there. We provideour completion specialists with ongoing classroom training tosupplement their field experience.Commitment to excellence. To ensure the safety of our personneland clients, we encourage a culture of excellence through ourEnterprise Excellence Process (EEP). Our EEP addresseseverything from total technical integrity assurancefor product/service delivery to continuous processimprovement in our day-to-day activities with our clients.Collaborative approach. Recognizing the important role thatcollaboration plays in the success of a project, we work closelywith your completion teams to develop a thorough understandingof your wells and objectives. We have completions engineeringteams in the Eastern and Western Hemispheres to provide morelocalized support. Also our dedicated Premium Completion Centerin Houston, Texas, serves as a global resource for our completionspecialists in the field.Project execution and management. Quality, reliability andefficiency are built in through a global network of Weatherfordmanufacturing and services facilities. While at the wellsite,installation success comes from the knowledge and theexperience that only an industry leader can provide. Ouroperational project management system provides the structurefor applying this experience with safety and efficiency.Research and development. With one of the strongest patentportfolios in the oilfield services industry, Weatherford is committedto enhancing existing products and to developing new ones.Our global network of R&D facilities brings you state-of-the-artcompletion technology and custom-engineered equipment. OurR&D efforts related to the Optimum upper-completion system areongoing, and we look forward to unveiling new design features asthey materialize.6 © 2011-2012 Weatherford. All rights reserved.

Optimum Upper-Completion SystemDiscover premium designThe Optimum system consists of an integrated array of highly durable upper‐completioncomponents, including an interventionless removable production packer, subsurfacesafety valve, multiple downhole control valves and flow-control equipment.Optimum Upper-Completion SystemOptiPkr removable production packer▪▪Large-bore removable packer▪▪No mandrel movement during packer setting▪▪Interventionless setting modules▪▪Modular design to meetoperational objective▪▪Qualified toISO 14310 V-0OptiSet valve▪▪Holds pressure from abovefor interventionless packer setting▪▪Self-filling▪▪Capable ofmultiple-pressurecyclesOptimax series subsurface safety systems▪▪Industry-leading reliability▪▪Nonelastomer rod-piston design▪▪Tubing and wireline retrievable models▪▪Ultradeep set and slimlineversion availableOptiSet FL isolation valve▪▪Minimizes fluid loss to the formationOptiBarrier isolation valve▪▪Contains fluids during completion▪▪Unique, opposing dual-curved flappers▪▪Bidirectional sealingOptiSleeve sliding sleeve▪▪One connection to minimize leak paths▪▪Chemically inert nonelastomer seals for exceptionalsealing in hostile environments▪▪Available in up-to-openor down-to-openUniset ® premium flow controls▪▪Simplicity of design eliminatesthe need for complexmanipulation downhole▪▪No-go principleminimizes thetaper effect© 2011-2012 Weatherford. All rights reserved.7

Production packer systemOptiPkr removable production packer system. Weatherford’s OptiPkr production packer is designed formaximal flexibility and durability. It offers the robustness of a permanent packer, while maintaining the flexibility ofa retrievable packer. Tested to ISO 14310-V0 standards, the highly modular OptiPkr system can handle extremedownhole pressures and temperatures. It is a removable (for higher tensile loads) production packer that can beconverted from hydraulic to hydrostatic, to RFID-set, as needed. In addition it is significantly shorter than moreconventional retrievable packers, which helps reduce risks in highly deviated wells. The OptiPkr packer is alsoideally suited for subsea environments, in which packer reliability is critical. With few components, its simplicityfurther enhances reliability.RFID technology. Available with the OptiPkr system, Weatherford’s RFID technology uses small, encoded tags anddownhole readers to automate packer functions. As such, it can render the OptiPkr system truly interventionless,enhancing efficiency, minimizing personnel requirements, and consequently reducing cost and risk.SealsanchoredSealsfloatingNo-sealspremiumthreadsThru-tubingcut extensionShear- Shear- Shear- Shear-releaseShear-ReleaseRelease ReleasemoduleReleaseModule Module Module Module ModuleShear-Shear-ReleaseReleaseModuleModuleOptiSet OptiSet OptiSet OptiSet OptiSetOptiSetPacker-Setting Packer-Setting Valve Packer-Setting Valve Valve Valve ValvevalveRFIDmoduleHydrostaticmoduleInterventionset8OptiSetOptiSetPacker-Setting Packer-Setting ValveValve Valve© 2011-2012 Weatherford. All rights reserved.

Optimum Upper-Completion SystemSubsurface Safety ValvesOptimax surface-controlled subsurfacesafety valves (SCSSVs). If surface controlsfail, Weatherford’s Optimax series SCSSVsprotect wellsite personnel, equipment and thesurrounding environment. The Optimax series’design incorporates nonelastomeric dynamicseals in a rod piston, providing longer well lifeand lower frictional forces. In addition, thisunique design provides reliable service for avast majority of well conditions.Our Optimax safety valves are available intubing- and wireline‐retrievable versions withpressure ratings of 5,000, 10,000 and 15,000 psi(34, 69 and 103 MPa); sizes ranging from2 3/8- to 7‐in. tubing; and a 350°F (177°C)temperature rating.With the best mean time before failure (MTBF)rate in the oil and gas industry, Optimax valvesare tested to standards that exceed API 14A,helping ensure their reliability in the field.To date, Weatherford’s Optimax valves have experiencedzero failures in the field. 18007006005004003002001000Asia/PacificEurope/West Africa/CIS 3Middle East/North AfricaGulf of MexicoCanadaConsolidated Service Life(Valve Years)Number ofTRSSSV 2 FailuresU.S. LandLatin AmericaMexico1Information is current as of December 2010. For a current list of our reliabilitystatistics, visit our website at weatherford.com.2Tubing-retrievable subsurface safety valve3Commonwealth of Independent States (formerly the USSR)Key FeaturesSelf-equalizing flappers. All Weatherford SCSSVs incorporatea metal-to-metal hard seat and a nonelastomeric resilient seal inthe flapper designs. This dual seal provides redundancy in gasapplications. The design of the optional through-the-flapper equalizingsystem is based on years of industry experience in the design anduse of self-equalizing valves.Rod-piston design. The multiseal rod-piston stack incorporates metalto-metalseals for accurate sealing engagement and accurate control.The strength of the design ensures best-in-class service, reducingcosts and providing longer well life.© 2011-2012 Weatherford. All rights reserved.9

Downhole Control ValvesOptiSleeve sliding sleeve. Operated with a shifting tool,the tubing-mounted OptiSleeve sliding sleeve enables theopening and closing of apertures between the tubing and annulusto regulate flow from producing zones. Its applications include isolatingproducing zones during installation of the inner string, circulating completionor kill fluids, and injecting water into select zones for waterflooding. The OptiSleevesliding sleeve’s nonelastomer seals and proprietary sealing threads help ensure sealingintegrity in hostile environments. It is rated for temperatures up to 350°F (190°C) andpressures up to 10,000 psi (69 MPa).OptiBarrier isolation valve. The OptiBarrier valve contains fluids fromabove and below during completion operations. Its multiple functionsinclude isolating the reservoir from completion fluids while running orretrieving the upper completion. Run in hole and tripped to close, thevalve is equipped with unique, opposing dual-curved flappers that enablebidirectional sealing, thereby enhancing sealing integrity and providinga true downhole barrier. Simple and easy-to-operate, the unique flapperdesign offers a larger ID than conventional ball valve designs.OptiSet valve. Installed below the packer, the OptiSetvalve enables interventionless packer setting, enhancingoperational efficiency and safety. Additionally, it is self-filling(tubing-to-tubing), which eliminates the need for—and cost of—aseparate auto-fill sub. A built-in contingency feature, the valve’s APIqualifiedaluminum flapper can be dissolved with acid in the unlikely eventthat the shear mechanism fails, minimizing the potential for nonproductive time.OptiSet fluid-loss (FL) isolation valve. The OptiSet FL isolation valve is used tominimize fluid loss to the formation when completing a well. Like the OptiSet valve, theOptiSet FL valve is equipped with an API-qualified aluminum flapper that can be dissolved withacid as a contingency measure.Flow ControlUniset ® flow-control system. The core of the Uniset system iscompletion optimization. The system consists of multiple, highperformanceflow-control accessories, including anti-blowout devices,equalizing assemblies, plugs and standing valves that optimizewell-completion designs. The Uniset system uses nipples for simple,reliable, low-cost well completion and servicing, as well as bridgeplugs for redundant well plugging later in the field’s life. The flexibleworking monobore design results in a well design that enables thrutubingretrievable bridge plugs to be run into the liner, yet still enablesthe use of landing nipples in the upper completions. The integratedsystem is rated for temperatures up to 400°F (204°C) and pressuresup to 20,000 psi (138 MPa).10 © 2011-2012 Weatherford. All rights reserved.

Optimum Upper-Completion System© 2011-2012 Weatherford. All rights reserved.11

Optimum Upper-Completion SystemDiscover premium performanceDiscover how Weatherford’s interventionless Optimum upper-completion system can helpyou avoid performance failures in harsh environments. Contact your local Weatherfordrepresentative, or visit weatherford.comweatherford.com© 2011-2012 Weatherford. All rights reserved. 7362.01Weatherford products and services are subject to the Company’s standard terms and conditions, available on request or at weatherford.com. For more information contact an authorized Weatherford representative. Unless notedotherwise, trademarks and service marks herein are the property of Weatherford and may be registered in the United States and/or other countries. Weatherford products named herein may be protected by one or more U.S.and/or foreign patents. For more information, contact patents@weatherford.com. Specifications are subject to change without notice. Weatherford sells its products and services in accordance with the terms and conditions setforth in the applicable contract between Weatherford and the client.