Weatherford SET

MetalSkin® Solid Expandable Systems for Open and Cased Hole Reduce installation risks while driving down well construction costs and mitigating drilling hazards.

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Building on our expandable heritage

1995

First commercial application of slotted alternative bore hole liner (ABL) tubulars

1999

Weatherford acquires Petroline and commercially launches the ESS system First horizontal ESS application

2000

Expandable experience Weatherford is the world's most experienced provider of ERC™ expandable reservoir completions using slotted and solid expandable products. We've been there. We've installed more than 450 ESS® expandable sand screen systems alone worldwide.

Weatherford begins developing solid expandables Record-setting ABL installation

Expansive thinking 2001

Weatherford’s longest ESS installation to date First multizone ESS application

2002

First Weatherford solid expandable liner hanger system installed First Weatherford MetalSkin cased-hole system deployed

2003

The 225th ESS installation

2004

More than 300 ESS systems have been installed around the world

2005

World’s first 7-in. expandable isolation system successfully installed

2006

New-generation MetalSkin open-hole liner successfully installed

2007

Commercial launch of new-generation MetalSkin systems

For well construction, completion and remediation applications, Weatherford has pioneered major advancements in expandable technology since the mid-1990s. The revolutionary ESS expandable sand screen changed the face of sand control, with our exclusive compliant tubular expansion eliminating annular space to enhance borehole support and sand filtration. Weatherford's slotted expandables experience provided a solid foundation for the development of solid expandables. One of the very first of our solid expandables innovations was our ABL® alternative borehole liner, introduced over a decade ago. We've transferred all of our slotted tubular application and operational experience to our MetalSkin® solid expandable open-hole and cased-hole products. These products provide unique solutions for any number of applications ranging from isolation of troublesome formations during drilling to casing repair.

Expanding understanding Weatherford has a deep understanding of the operational envelopes of expanding solid tubulars in wells. We know how to engineer a low-risk installation. And we've conducted detailed studies of more than 100 of our installations to further deepen our understanding.

Expanded coverage Weatherford expandables are supported by a worldwide network that includes two of the industry's largest R&D, testing and training facilities. We custom-build expandable systems at our eastern- and westernhemisphere manufacturing facilities.

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© 2007 Weatherford. All rights reserved.

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solid reasons why MetalSkin expandables are

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The full potential of solid tubular expandable technology to revolutionize well construction is now being realized. Weatherford's newgeneration MetalSkin solid expandables are reducing installation risks while driving down construction costs and minimizing drilling hazards.

MetalSkin systems leverage cutting-edge technologies to provide critical performance advantages. The systems are far less problematic and more cost efficient than first-generation expandables. In fact, these advanced expandable systems offer seven significant advantages that can spell the difference between success and failure.

Solid performance advantages

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Slimmer system design provides greater running clearance to avoid problems associated with equivalent circulation density (ECD) and differential sticking.

2

Collapsible expansion cones facilitate contingency retrieval.

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Fully qualified premium metal-to-metal expandable connectors provide unmatched performance and reliability.

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Work-string/liner interface design prevents premature initiation of expansion as the expandable system is worked to bottom.

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Elastomer sealing elements provide positive zonal isolation without cementing.

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Hydraulically assisted backup expansion system reduces contingency costs.

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Lower expansion pressure requirement and high-integrity circulation valve enhance expansion reliability.

© 2007 Weatherford. All rights reserved.

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MetalSkin open-hole liner systems maximize your field's ROI by reducing construction costs with slimmer tophole casing sections while upsizing the completion. Isolate problem zones, and drill ahead.

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© 2007 Weatherford. All rights reserved.

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MetalSkin monobore open-hole clad systems selectively isolate trouble zones as they are encountered so that drilling can continue without sacrificing hole size. After the clad is expanded to seal the zone, another clad can be passed through it to treat the next trouble zone encountered.

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MetalSkin cased-hole liner systems answer mature-field challenges by permanently repairing corroded or parted casing. Elastomer seal bands give more reliable zonal isolation than cement squeezes and don't significantly reduce well ID as do scab liners.

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MetalSkin monobore open-hole liner systems let you gain an extra string of casing with no loss of hole size. Drill out with the same size bit. Remediate drilling hazards such as lost circulation and overpressured zones. © 2007 Weatherford. All rights reserved.

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MetalSkin® open-hole liner system Solid ideas for expanding your options The MetalSkin open-hole liner system is a solid expandable drilling liner that reduces well construction costs with the ability to provide an additional casing string while conserving hole size. This system enables the drilling of previously undrillable wells. Pre-planned operations: Maximize your field's ROI by increasing hole size and exposure in the reservoir and upsizing the well's completion. Reduce construction costs by maintaining the required well geometry through the reservoir while slimming down the top-hole casing sections. Contingency applications: The MetalSkin system helps mitigate drilling hazards by letting you isolate problem zones and drill ahead without resorting to downsizing the well's completion. Remediating well construction challenges: The MetalSkin system effectively deals with lost-circulation zones, overpressured formations, zones with shallow flows, and premature casing sets.

Bottom-up expansion The MetalSkin system eliminates risk-inducing factors such as tight running clearances, nonretrievable cones and underreaming. Bottom-up expansion of the system is hydraulically assisted with the use of a unique collapsible cone. Systems are available in lengths up to 6,500 ft (1,981 m).

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© 2007 Weatherford. All rights reserved.

Conventional Well Design

MetalSkin Well Design

20 in.

16 in.

16 in.

Solid advantages and benefits

13-3/8 in.

13-3/8 in.

11-3/4 in.

Unique design maximizes running clearance to minimize effect on ECD and run time; helps avoid differential sticking. 11-3/4 in.

Optimal-yield base pipe reduces expansion pressure requirements by 33 percent to reduce operational risk and maintain the integrity of the liner and its post-expansion collapse resistance.

9-5/8 in.

9-5/8 in.

7 5/8- x 9 5/8-in. solid expandable system

Collapsible, retrievable expansion cone avoids becoming stuck by retracting for retrieval at any time—even when the pipe is only partially expanded. 7 in.

7 in.

Metal-to-metal expandable connectors exceed proposed API standards in testing for burst, collapse, tensile and compressional resistance. Hydraulically assisted expansion balances pressure across the cone so that a seal does not form on the cone face and forces tending to swage the cone are minimized, greatly improving system reliability and avoiding the risk of flow erosion of the casing. Hydraulic jack reduces risk of costly delays by serving as a backup system to resume expansion of the casing in the event pressure is lost during expansion. Primary pressure seal contains expansion pressure with much greater consistency through the use of a valve system rather than relying on the use of darts to create and maintain the system's pressure seal. Elastomer sealing elements reduce well construction costs and risks by providing zonal isolation without underreaming and cementing.

The MetalSkin system cuts well construction costs by reducing the need to telescope down to smaller and smaller casing sizes. You can start drilling with smaller-diameter upper-hole sections and finish with the same size or larger hole sections for optimal production string sizes.

Running sequence

1

Run in hole, and circulate.

2

Drop ball, assemble cone and expand launcher.

3

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Cement well (if required).

Close seal valve, and expand liner.

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Expand liner hanger.

Drill out shoe.

© 2007 Weatherford. All rights reserved.

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Gain a string without losing hole size The MetalSkin monobore open-hole liner system eliminates the slimming of a well profile during well construction. An oversized shoe is run into the hole with the previous string of casing, and the liner extension is then run to total depth and expanded back into the oversized shoe. This technique provides a string with the same diameter as the one above it. You gain a string of casing with no loss of hole size. Drill-out is made with the same size bit. Planned contingency operations: Running the oversized shoe with the previous string doesn't lock you into running the MetalSkin monobore open-hole liner system. You can choose to run another string of conventional casing. Remediating well construction challenges: Lost-circulation zones, overpressured formations and zones with shallow flows. These and other problems encountered downhole are minimized with the MetalSkin monobore open-hole liner system.

MetalSkin monobore oversized shoe After it is installed at the bottom of the previous casing string, the oversized shoe can be drilled out with conventional bottomhole drilling assemblies. This simple design provides a full bore in the overlap between the monobore open-hole liner system and the parent casing string, reducing operational risk by eliminating the need to over-expand the shoe track to receive the expanding MetalSkin system.

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© 2007 Weatherford. All rights reserved.

Conventional Well Design

MetalSkin Well Design

18-5/8 in. casing

18-5/8 in.

13-3/8 in.

13-3/8 in. casing with Weatherford 14 1/2-in. oversized shoe

Solid advantages and benefits Unique design maximizes running clearance to minimize effect on ECD and run time; helps avoid differential sticking.

9-5/8 in.

11 3/4-in. ´ 13 3/8-in. MetalSkin monobore open-hole liner

Optimal-yield base pipe reduces expansion pressure requirements by 33 percent to reduce operational risk and maintain the integrity of the liner and its post-expansion collapse resistance. 7-in. casing/liner

9 5/8-in. casing

Oversized shoe with flush joint connector facilitates drill-out with no loss of hole size. High-collapse-resistance casing enhances reliability with the ability to withstand high external pressures.

5-in. liner

7-in. liner

Collapsible, retrievable expansion cone avoids becoming stuck by retracting for retrieval at any time—even when the pipe is only partially expanded. Metal-to-metal expandable connectors exceed proposed API standards in testing for burst, collapse, tensile and compressional resistance. Hydraulically assisted expansion balances pressure across the cone so that a seal does not form on the cone face and forces tending to swage the cone are minimized, greatly improving system reliability and avoiding the risk of flow erosion of the casing. Hydraulic jack reduces risk of costly delays by serving as a backup system to resume expansion of the casing in the event pressure is lost during expansion. Primary pressure seal contains expansion pressure with much greater consistency through the use of a valve system rather than relying on the use of darts to create and maintain the system's pressure seal.

The MetalSkin system improves well productivity and reservoir recovery. You can complete the reservoir section in a larger hole size and with one casing string fewer to surface.

Elastomer sealing elements reduce well construction costs and risks by expanding to form an expandable liner hanger. Elastomer sealing elements placed on the expandable casing can be used to obtain zonal isolation without underreaming and without cementing.

Running sequence

1

Install base casing with oversized shoe.

2

Drill out shoe, and underream hole section.

3

Run in hole with monobore open-hole liner system.

4

Cement well (if required), assemble cone and initiate expansion.

5

Expand monobore shoe extension system.

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Expand liner hanger.

Drill out shoe.

© 2007 Weatherford. All rights reserved.

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MetalSkin® cased-hole liner system Solid answers to mature-field challenges The MetalSkin cased-hole liner system is designed to deal with challenges such as excessive water production, reservoir sweep inefficiency and aging wells. The threaded expandable tubular joints can be connected to create a system of any length. The system is a permanent solution that bridges the gap between cement squeezing and scab liners while conserving hole size. Solid remediation solutions: Using expandable threaded casing, the MetalSkin cased-hole liner system provides solid remediation solutions. The system has high burst and collapse resistance and provides a longterm seal against deformed, worn, corroded, eroded or parted casing. MetalSkin liners are ideal for casing off perforations and bad casing so that you can selectively reperforate to access bypassed pay. And the liners greatly facilitate deepening of mature wells. Alternative to cement squeezes and straddle packers: The MetalSkin system gives you a solid alternative to cement squeezes and straddle packers for permanent zonal isolation. The double security of an expanded liner plus elastomer seal elements that are molded to the OD makes the MetalSkin system more reliable than a cement squeeze. And with the MetalSkin system, you end up with an ID that is larger than possible with a straddle packer. Shutting off unwanted water: The MetalSkin cased-hole liner system is effective for shutting off unwanted water and enhancing oil production. It also provides positive sealing of laterals and sidetrack windows, depleted production zones and injection intervals as well as unwanted perforations. You can solve reservoir sweep inefficiency problems by permanently sealing off thief zones in injection wells created by bad pipe or unwanted perforations. The system is also ideal for remediating subsidence-damaged casing. The MetalSkin system provides superior efficiency and economy, requiring no drill-out as with other expandable cased-hole liners and conventional systems.

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© 2007 Weatherford. All rights reserved.

Solid advantages and benefits Elastomer sealing elements aid pressure containment by expanding between the cased-hole liner and the parent casing to seal across the problem area. The result is more positive and permanent zonal isolation than with a cement squeeze through a straddle packer. And the MetalSkin liner has a larger ID than the packer system to facilitate access to lower zones. The MetalSkin system also helps avoid multiple cement squeezes, which result in downtime and reduced reservoir recovery. Large ID for the full length of the expandable system maximizes production and injection rates and provides better access for future intervention operations. Launcherless system increases operational reliability by avoiding surge problems or becoming stuck, as can happen with oversized launchers (cone housings) or shoes. With the MetalSkin system, the cone is run below the expandable casing; so no launcher is required. Hydraulic jack protects casing and connectors because the expansion pressure is contained within the jack rather than subjecting tubulars to expansion pressure cycles.

A MetalSkin cased-hole liner system can be set as a packer seat to enable fracturing of lower bypassed pay. A second MetalSkin system can be used to isolate watered-out upper perforations before selective re-perforating.

Running sequence

1

Run bit and scraper to clean corrosion from base over interval to be remediated.

2

Run in hole with the MetalSkin casedhole liner.

3

Expand the MetalSkin anchor with the running tool.

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Continue expanding the MetalSkin liner with direct pull.

Cone exits top of fully expanded MetalSkin liner, and expansion tools are retrieved.

© 2007 Weatherford. All rights reserved.

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Solid answers for drilling hazard mitigation The MetalSkin monobore open-hole clad system is a solid expandable system for solving wellbore problems and mitigating hazards. It provides a much faster and more cost-efficient method than pumping thicker muds and cement in an attempt to seal a formation or stabilize a sloughing formation. The solid steel barrier keeps the formation from falling in and fluid from flowing out. Wellbore instability and lost-circulation problems: This low-risk MetalSkin system provides zero loss of hole size after installation. Multiple clads can be run (passing one clad through another—a clad-through-clad effect) to provide the same drift as the hole after installation. Zonal isolation is achieved without tying the system back to the previous casing shoe. The system is ideal for treating lost-circulation zones, overpressured formations, zones with shallow flows and sloughing formations. Solid drilling security: The MetalSkin monobore open-hole clad system mitigates the risks of drilling trouble zones without forcing you to line the entire wellbore. The trouble zone is minimally underreamed (1.0 in.), and the clad system is expanded into it. You can then resume drilling with the same size bit (because the clad allows full bore access) and complete the well as planned, without downsizing.

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© 2007 Weatherford. All rights reserved.

Conventional Well Design

MetalSkin Well Design

18-5/8 in.

9-5/8 in.

13-3/8 in.

Solid advantages and benefits 9-5/8 in.

Selective isolation reduces risk exposure and costs because the MetalSkin monobore open-hole clad system is typically short and is not tied back to the casing. You isolate only the area that needs attention, such as sealing off trouble zones. Clad-through-clad flexibility lets you run and expand a clad to seal off one trouble zone, continue drilling with the same size bit, and run additional MetalSkin open-hole clad systems to resolve any additional problems encountered farther downhole.

7-in. casing/liner

7-in. liner

5-in. liner

5-in. liner

Mitigate the risks of drilling trouble zones without having to line the entire wellbore. MetalSkin clad systems are typically only 100 to 750 ft (30 to 229 m) in length, which minimizes operational risks and installation costs. No loss of hole size means optimal production and intervention access. Only a 1-in. underream is needed to allow the system to be completely recessed into the wellbore. Elastomer bands wherever required along the system's length create pipe-to-formation seals and promote the positive anchoring of the MetalSkin monobore open-hole clad system.

After the MetalSkin monobore openhole clad is expanded to seal a trouble zone, another clad can be passed through it to isolate the next trouble zone encountered. Drilling can proceed to the planned total depth of the hole section, at which point a conventionally cemented casing program can be installed.

The monobore effect of the MetalSkin open-hole clad system lets you slim the well to reduce well construction costs. Drilling a smaller hole, using smaller-size casing in the upper sections, and using little or no cement create significant savings of time and materials while maintaining an optimal size completion.

Running sequence

1

Bi-center drill or ream wellbore in the trouble interval.

2

Run the MetalSkin system in hole, and begin to expand the bottom hanger.

3

Expand the clad.

4

5

Expand the top clad, and pull out of hole with the running tool.

Drill ahead with no loss of hole size.

© 2007 Weatherford. All rights reserved.

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New-generation solid expandable systems Weatherford's MetalSkin systems are the most advanced solid expandables available today. Now is a good time to learn how they can help reduce your well construction costs, mitigate drilling hazards and increase reservoir exposure and production. Talk to the world's most experienced expandable experts with the most advanced line of products. Find out more at www.weatherford.com/metalskin.

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© 2007 Weatherford. All rights reserved.

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The Solid Choice™ from the expandable experts.

515 Post Oak Blvd., Suite 600 Houston, Texas 77027 Tel: 713-693-4000 www.weatherford.com

Weatherford products and services are subject to the Company’s standard terms and conditions, available on request or at www.weatherford.com. For more information contact an authorized Weatherford representative. Unless noted otherwise, trademarks and service marks herein are the property of Weatherford. Specifications are subject to change without notice. Weatherford sells its products and services in accordance with the terms and conditions set forth in the applicable contract between Weatherford and the client. © 2007 Weatherford. All rights reserved.

Brochure 3211.00