Acknowledgements

We wish to thank the following people for their

contributions to this course:

Greg Galloway
Doug Farley
Alex Ngan
Randy Romman
Luis Godoy
Subject Matter Experts
Calum Jack
Graphic Design
Bill Ward
Instructional Design
Adele Hanas
Photography
Implementation Team
EMPLOYEE connect

| WFT_v2.1_20140620 |
Table of Contents
Table of Contents
Module 1: Introduction to Solid Expandable Systems.................................................................. 5

Module 2: Cased Hole Products.................................................................................................. 46

Module 3: Open Hole Products .................................................................................................. 77

Module 4: Successful Sales ...................................................................................................... 105

Common Terms......................................................................................................................... 119

Appendix ................................................................................................................................... 126

Activities .................................................................................................................................... 131

©2014 Weatherford International. All rights reserved 1

Course Introduction

In this course the focus is on Solid Expandable Systems and their relevance to drilling and well
remediation applications.

 Solid Expandable Systems provide value during well construction by reducing drilling
costs, maximizing target depth hole size, increasing production opportunities by
optimizing completion size, and providing a means of mitigating drilling hazards without
deviating from the basis of design.

 Solid Expandable Systems provide value in existing wells by providing a permanent, one
time solution for casing remediation and zonal isolation challenges while maximizing
pass through ID for future operations.

The purpose of this course is to:

 Define the role of Solid Expandable Systems in wellbore operations.

 Identify and explain Weatherford Solid Expandable Systems products and their
applications.

 Identify and explain applications for Solid Expandable Systems in open and cased hole
environments.

 Increase awareness of support structure for successful sales of Solid Expandable

Systems products.

©2014 Weatherford International. All rights reserved 2

Course Learning Objectives

Upon completion of this course, you should be able to:

 Describe the role of Weatherford Solid Expandable Systems in wellbore operations.

 Identify and explain the functionality of Weatherford’s Solid Expandable Systems.

 Identify and explain the applications of Weatherford’s Solid Expandable Systems.

 Use the resources available to support the sales of Solid Expandable Systems.

©2014 Weatherford International. All rights reserved 3

 Icebreaker Activity

What is your perception of Solid Expandable Systems?

Take a moment to write your thoughts below:

©2014 Weatherford International. All rights reserved 4

 Chapter 1: Introduction to Solid Expandable Systems

Chapter 1 Learning Objectives

Upon completion of this chapter you should be able to:

 Define the function of Solid Expandable Systems.

 Describe the benefits of Solid Expandable Systems.

 Identify and explain the components and attributes of Solid Expandable Systems.

 Describe Solid Expandable Systems product quality.

 Identify the role of Solid Expandable Systems in relation to a customer’s needs.

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Module 1 Successful Sales

Chapter 1 Overview
In this chapter we will review the following:

 Definition of Solid Expandable Technology.

 Components of Solid Expandable Systems.

 Solid Expandable Systems quality support.

 The role of Solid Expandable Systems in wellbore operations.

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Solid Expandable Systems

Expandable Technology is based on a process of cold working or forming tubular products
downhole to eliminate or minimize the telescopic effect in well construction and maximize
pass through ID during casing remediation.

The process of swaging allows the casing used for solid expandable products to be expanded
into a larger size casing using cone expansion. Solid expandable casing enlarges via a cold
working process where the casing is stretched beyond the elastic limit, or yield point, but
below the ultimate tensile limit. This region, between the elastic limit and the ultimate tensile
limit, is known as the plastic region. The process permanently deforms the pipe without
breaking it, increases the yield strength, and decreases the malleability of the metal.

Image 1.1: Cold working process

The telescoping effect occurs in all wells due to the need to set casing across certain formations
prior to drilling deeper in the well. Therefore, each subsequent set of casing must be smaller
than the one before it, causing the well to telescope. These casing seats are usually driven by
pore pressure and fracture gradient windows.

Drilling in areas that are prone to drilling problems (sloughing shales, lost circulation zones,
etc.) can add additional casing seats to the basis of design (or worse, additional casing seats

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that were not planned into the basis of design) which further minimizes the ID downhole.
These issues further exasperate the telescoping effect. Solid Expandable Systems help to
overcome these challenges by providing the necessary zonal isolation to mitigate the drilling
hazard but still allow maximum hole size at TD.

Image 1.2: Telescoping well design

In cased hole situations, the objective of the Solid Expandable System is to maximize pass
through ID during casing remediation operations. By maximizing pass through ID, the operator
has more options for future well interventions. These options include, but are not limited to:

 Larger completion

 Facilitating re-entry

 Larger well intervention tools

 More options over the life of the well

The Development of Solid Expandables

Weatherford started the Solid Expandable Systems Product Line in 2002; however, this was not
the first time that Weatherford was involved with expanding pipe.

In 1991 Weatherford acquired a company, Houston Oilfield and Material Company, which had
been setting expandable patches since the 1960’s. These patches are unique corrugated liners
that are available in short 20’ sections and require on-site welding for extended length patches.

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Under the Weatherford umbrella, this system was named HOMCO and over 10,000 patches
have been installed to date in wells across the world.

In 2002, Weatherford took the idea of the HOMCO patch and decided to take it a step further;
creating jointed expandable connections with thicker wall pipe was the new goal. First,
Weatherford experimented with Rotary Expansion Tools with much success but it was still not
an optimal design. After collaborating with Shell, Weatherford acquired a license to perform
“Solid Cone Expansion”.

With this license, Weatherford began working internally to develop expandable connections
and the first MetalSkin® Cased Hole Liner was developed. The success of this system became a
catalyst for new development, with operators such as Saudi Aramco and BP contributing to the
development of open hole expandable systems known commercially as MetalSkin® Open Hole
Liners. Since then, Weatherford’s R&D team has been developing new and innovative
expansion products that further benefit our clients.

Solid Expandable Systems: The One Weatherford Approach

Weatherford’s Solid Expandable Systems represent a great example of the ONE Weatherford
approach. Well preparation is critical for any expandable job which requires support from
multiple product lines. For example, before an expandable open hole liner is run, under-
reaming, logging and a drift BHA may be required. By working in line with the pull through
concept, we can provide a “turnkey” operation for the client. Pull through opportunities are
present during each operation and can assist during well preparation, running the expandable
liner, and after installation of the expandable liner.

Typically, Solid Expandable Systems provide pull through opportunities for the following
product lines:

 Cased-hole Logging

 Cased-hole Completions

 Under-reamers

 Fishing and Rentals

 Tubular Running Services (TRS)

 Wellbore clean out

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Why Use Solid Expandable Systems Products?

Solid Expandable Systems products have proven to be valuable for:

 Drilling rigs by providing open-hole solutions

• Reducing nonproductive time

 Workover rigs by providing cased-hole solutions

When used in drilling operations, Solid Expandables can increase casing size at total depth and
provide additional casing strings to the basis of design without downsizing the well hole
diameter at TD. Solid Expandable Systems can also allow for the reduction of casing strings
from the onset which reduces drilling costs.

Open-hole solutions

Solid Expandable Systems open-hole solutions include:

 MetalSkin® Open-Hole Liner which allows for isolating problem zones with increased
pass through ID compared to a conventional line

 MetalSkin® Monobore Open-Hole Liner isolates problem zones with zero loss of hole
size

 MetalSkin® Monobore Open-Hole Clad able to selectively isolate problem zones

without having to tieback into the host casing and provide a pass through ID equal to
the previous casing drift

Solid expandables can increase production options on work-over rigs by providing greater pass
through ID when compared to conventional products such as straddle packers. The technology
is designed to provide the hole size needed to facilitate re-entry, perform well intervention
operations, and allow for optimal sized completion options.

Reducing Non-Productive Time

Non-Productive time (NPT) costs the industry billions of dollars a year and while expandables
cannot reduce costs associated with issues such as rig equipment failures or delays due to
weather conditions, expandables can reduce NPT associated with high pressure or low pressure
zones, wellbore instability and other drilling hazards.

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Image 1.3: Causes of Non-Productive time

Expandable Technology reduces Non-Productive Time by:

 Decreasing high pressure event cost (kicks, flows)

 Decreasing low pressure event cost (lost circulation)

 Reducing wellbore instability event cost (twist-off, stuck pipe)

 Improving well intervention efficiency

Cased-hole solutions

Solid Expandable Systems cased-hole solutions include:

 MetalSkin® Casd-Hole Liner

 HOMCO® Internal Steel Casing Patch
The value of the MetalSkin® Cased-Hole Liner is two-fold; the system is permanent and,
provides a larger through bore than other mechanical solutions. Once installed, drilling,
stimulation, completion or injection operations can begin, all with one objective: place larger
pipe into the production zone.

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Image 1.4: Capabilities of Solid Expandable Systems

The Homco® Internal Steel Casing Patch is similar to the MetalSkin® Cased Hole Liner in that it
also provides a one-time permanent solution to zonal isolation challenges in existing wells.
However, the HOMCO system has different characteristics than the MetalSkin® system and is
better suited for certain applications which will be explored in detail later in the course.

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Components of Solid Expandable Systems Products

Five primary components make up Solid Expandable Systems products.

 Tubulars

 Connections

 Elastomers / Swellable Elements

 Lubrication

 Expansion Tools

Tubulars
The tubulars used for Solid Expandable Systems products are made from certain grades of pipe
that are manufactured to tighter tolerances than are allowed by API. Solid Expandable tubulars
are more malleable and designed with optimal thickness to allow for expansion at reasonable
forces and to provide clearance for the subsequent casing string.

Image 1.5: Tubulars

Expansion pressure vs. Burst pressure

It is critical to understand the limits of expanding pipe, most notably the balance of expansion
pressure vs. yield pressure. For example, expansion with a cone driven by internal pressure
above 25% is not practical because the expansion pressure required is exceptionally close to
the ultimate tensile strength.

Therefore, the higher the expansion ratio and the increased associated expansion pressure
must be considered and balanced with the pipe internal yield rating.

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The expansion ratio is calculated from pre and post expanded ID of the tubular.

If ID1= pre expanded ID and ID2 = post expanded ID, then the expansion ratio is calculated as
follows: (ID2-ID1)/ID1 = Expansion Ratio

Image 1.6: Percent Expansion vs. Internal Pressure

High expansion ratio

High expansion ratios also significantly reduce the collapse rating of pipe due to the D/t ratio,
the Bauschinger Effect, and increased wall thinning, which is estimated at 2*(expansion
ratio)/3.

D/t Ratio

During fixed-free expansion, the diameter is increased during the expansion process but the
thickness is held constant, which means that the D/t ratio will increase. This factor is inversely
proportional to the collapse rating of expanded tubulars which is why the larger the factor, the
lower the collapse rating of the post expanded pipe. However, there are two ways to minimize
this effect:

1. Decrease the amount of expansion ratio (and therefore decrease the D=Diameter) or

2. Increase the thickness of our expandable pipe which would require greater expansion
pressures.

Bauschinger Effect

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The higher the expansion ratio, the more significant the Bauschinger effect on the tubular. The
Bauschinger effect is described as residual stresses in the hoop direction, which are caused by
cold working, and tend to try reverting the tubular to its original geometry.

The Bauschinger Effect accounts for the reduction in collapse rating for expanded tubulars only
and is not comparable to a normal unexpanded sample of the same geometry and yield
strength.

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Defect Tolerance

The higher the expansion ratio, the more defects affect performance.

The defect tolerances of Solid Expandable tubulars are:

7% of the casing’s longitudinal wall thickness
10% of the radial wall thickness

Connections
Connections are a critical component of Solid Expandable Systems products. Historically, the
connections are the most important and limiting factor of expanding tubulars. After expansion,
the threads are distorted and the expandable is still expected to hold pressure on the order of
several thousand psi. Additionally, expandable connections are required to hold pressure
before and during expansion as well.

Expandable connections are also sensitive to defects which can compromise the connection
during expansion. The defect tolerance for the box end is 3% compared to 10% for radial wall
thickness

Since expandable connections are much more sensitive to defects than expandable pipe (due to
minimal wall thickness at both the pin and box of the connection), a protective connection
sleeve is glued on to the connections to minimize the potential for defects or scarring while
running the connections downhole.

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Assuming our expandable pipe has a wall thickness of 0.375”, a 10% allowable radial defect
would be about 0.038” of the wall thickness. This is acceptable and should not cause any
problems when expanding downhole.

However, the box portion of a connection is extremely thin, and allowing a 10% defect on such
a thin wall could cause problems during expansion. For instance, if the thinnest portion of the
box is 0.075”, a 10% defect would be about 0.008”. Although the ratio of acceptable defect is
the same as with a tubular, the amount of actual “non-defected” thickness is extremely small.
As a result, the engineering department determined that a maximum 3% defect is allowable on
the box connection; otherwise there is an increased risk of problems during expansion.

Image 1.7: Solid Expandable System connection

The connections for Solid Expandable products are flush or near flush in order to reduce stress
during expansion. Weatherford’s expandable connections use either a rubber to metal seal, or
a metal-to-metal seal. Currently, Weatherford manufactures the FODC-OR (Flush Outside
Diameter Connection – O Ring), WTXC (Weatherford Thread Expandable Connection), and R2M
(Rubber 2 Metal) connections. The VAM EWT/VAM ET Wise connections are provided by VAM.

The connection design group is constantly working to provide dependable gas tight metal to
metal connections with improved strength to withstand greater bending, tensional,
compressional, and torsional loads.

Connection Types

 VAM ET-WISE Premium

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 Weatherford FODC-OR

 Weatherford R2M

 WTXC

VAM ET-WISE Premium Connection

VAM’s ET-WISE connection is designed by VAM for Weatherford expandable applications in

collaboration with BP.
 It is an integral connection with threads that are left handed.

 Metal-to-metal seal giving a liquid tight connection.

Image 1.8: Solid Expandable System VAM ET Wise connection

Available Sizes:

 5 ½” .304 wall (50Ksi)

 7 5/8” .375 wall (50Ksi)

 8” .375 wall (50Ksi) - MMOC

 11 ¾” .600 wall (50Ksi)

Weatherford FODC-OR

Weatherford’s two step straight thread with O-ring.

 Mainly used in cased-hole remediation

 Gas tight applications with O-ring seal

 Designed for SES of 3 ½” OD to 7 5/8”

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Image 1.9: Pre and Post Expanded FODC-OR Connection

Available Sizes:

 3 ½” OD .254 wall (80 Ksi)

 4 ¼” OD .250 wall (50 Ksi)

 5 ½” OD .304 wall (50 Ksi)

 6” OD .324 wall (50 Ksi)

 7 5/8” OD .375 wall (50 Ksi)

Weatherford R2M Connection

 Dual O-ring seal / tapered connection

 Hydraulic expansion system

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Image 1.10: R2M Expandable Connection

Available Sizes:

 5 ½” OD .304 wall (50 Ksi)

 6” OD .324 wall (50 Ksi)

 7 5/8” OD .375 wall (50 Ksi)

 10 ¾” .350 wall (50 Ksi)

WTXC – Rubber to Metal

 Designed for SES larger than 7 5/8” OD

 Heavier wall thickness to increase pressure and mechanical post expansion capabilities

 Tapered thread design

 O-rings at both ends of the connection

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Image 1.11: WTXC Connection

Available Sizes:

 9 5/8” OD .352 wall (80 Ksi)

 11 ¾” OD .6 wall (50 Ksi)

Elastomers and Swellables

The elastomers and swellables used in Solid Expandable Systems products are utilized to seal
into host casing and provide zonal isolation in cased hole situations and to provide an anchoring
force for the expanded liner.

Another application of the elastomers and swellables is for use along the entire length of the
expandable liner when cement is not used in an open hole application. Swellable elastomers
can be activated with either water or oil based fluids, depending on the compound selection of
the swellable. The material will swell to the ID of the wellbore, creating a seal between the
expandable pipe and the formation. Swellables are particularly effective in open hole situations
because of their ability to swell to the non-uniform ID of a wellbore.

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The material used for the elastomers on the expandable liners have a maximum temperature
rating of 300°F and is similar to the materials used in current Weatherford packers. Higher
temperature elastomers are available for special cases but must be specially manufactured.

NOTE: Elastomeric sealing elements and thin wall steel connection sleeves are utilized on the
expandable liner in order to protect the connections while running in downhole.

Image 1.12: Elastomers on a Solid Expandables System

Lubrication
Lubrication is another critical component of expanding pipe. Without a reduction in friction,
the cone could become stuck during expansion and gall the inside of the liner. Weatherford’s
expandable liners are coated with a proprietary lubrication material used to reduce friction
during the expansion process.

Expansion Tools
The current method being utilized by Weatherford to expand tubulars is solid cone expansion.
The solid cone is a simple and reliable method for swaging and expanding pipe. Typically the
cone is deployed in the launcher or cone housing which is at the bottom of the expandable
liner. Once the expandable liner reaches setting depth, the cone is pumped from the bottom
up in a hydraulic expansion process, expanding pipe as it travels. Once the liner has been
completely expanded, there is a small post expansion annulus between the host casing and the
expandable liner which leaves room for the elastomers to seal into the host casing.

One important aspect to note when expanding from the bottom up is that pipe is in a “fixed-
free” scenario at this point. The pipe is fixed in place at the bottom of the liner due to the high
hydraulic pressure holding the liner in place at the bottom of the well and free at the top of the
liner (which is exposed and equalized with the rest of the wellbore).

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During expansion, the diameter of the liner is increased, thus the linear material volume is
increased. Due to conservation of mass, the liner shrinks from the top (known as the “free”
end) in order to provide the extra material needed for the increased tubular diameter.

It is possible to be in a “fixed-fixed” situation during expansion if the liner becomes

differentially stuck at the top and is unable to shrink. At this point the liner would experience a
reduction in wall thickness during expansion in order to allow for the increased diameter.

Figure Image 1.13: Solid Cone Expansion

Solid Expandable Systems Product Quality

Weatherford’s Oil Country Tubular Goods Technology Center (OCTG) in Huntsville, Texas
provides industry-leading capabilities for testing and manufacturing Solid Expandable Systems
products through the use of:

 Connection Engineering

 DLX – Dynamic Load Expansion Bench

 Prep Lab

 Prototype Manufacturing

 Analysis

 Materials specifications

Solid Expandable Systems products are also supported by research and development testing
resources in Houston, Texas with a dedicated solid expandables engineering team and full scale
on site test rig for qualifying new systems.

Connection Engineering

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ISO 13679 + API RP-5EX

The API and ISO both adopted standards to be used by all providers relating to connection
qualification and testing. In many ways these standards are identical. The API standard is API-
5C5 and the ISO standard is called ISO 13679. Many operators rely on these standards while
others have adopted a more stringent requirement for the qualification testing of threaded
downhole tubular connections.

These standards have well-defined procedures for every aspect of testing tubular connections
including the manufacture of the test samples, the makeup and break out and the actual
testing. However, these tests are for connections that have been manufactured on pipe and
are not expanded.

Furthermore, what ISO 13679 and API 5C5 do not address are control procedures for the
expansion of the test samples and the testing requirements after expansion.

To address expandable tubulars, the API formed a work group to provide guidance on
qualification and testing of expandable connections. The study group created a “Recommended
Practice” identified as API RP 5-EX. Adoption of the Recommended Practice is expected in April
2014 and once adopted will become an appendix to API 5C5 and by association to ISO 13679.

A key component of API RP 5-EX is requirement: “The expansion test shall reproduce the
conditions experienced downhole”. Weatherford developed and patented a one of a kind
testing tool to ensure downhole condition can be replicated in lab conditions to meet the
qualification requirements. This tool is called the DLX.

Von Mises Testing

Von Mises testing is required in most parts of ISO 13679 and API 5-EX. It simply means that all
combinations of mechanical loads and pressures can be evaluated together.

The X-Axis represents tension on the right and compression on the left. The upper half of the
plot represents internal pressure while the lower half represents external pressure.

When testing unexpanded connections, the pipe and the connections have fairly
straightforward performance envelopes. But when qualifying connections for expandable
application, the performance envelopes will change because of the change in material
properties and pipe / connection dimensions.

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Here, the blue envelope represents the connection’s capabilities in the unexpanded state. The
red presents its expanded state. This is another reason that expandable connections must be
tested in both the pre and post expanded conditions.

Image 1.14: Pre and Post Expanded Load Diagrams

RP 5-EX – 3 Key Tests

 RP5 EX Pre Expansion Test: To perform meaningful testing on connections for downhole
expansion, tests are required before expansion and after expansion. You, the user,
must know that the connections work while running downhole.

 RP 5-EX Expansion Test: This test outlines and controls the conditions of expansion.

 RP 5-EX Post Expansion Test: Lastly, RP 5-Ex will have procedures for the testing of
expanded connections which are currently under development in coordination with API.

DLX-Dynamic Load Expansion Bench

The tension and compression loads an expandable connection is subject to depends on the
length of the liner and where the connection is in the liner. Weatherford’s OCTG lab uses a

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Dynamic Load Expansion Bench to simulate compressive and tensile loading during expansion in
downhole environments. This ensures quality and reliability by eliminating as many unknowns
as possible. Weatherford is the only Solid Expandable Systems provider with the capability of
simulating true downhole conditions in a single expansion test.

NOTE: For more information about the DLX features and capabilities go to the Solid
Expandables Portal and/or ask a Weatherford OCTG representative.

These tests include the ability to simulate:

 Constant curvature expansion

 Deviations of up to 20°/100’

 Fixed-Free and Fixed-Fixed Expansion

 Extended length liners

For example, Weatherford is able to simulate expanding 2,500’ of 11-3/4” expandable liner
with the DLX. This liner can be tested to simulate an expansion force of 400,000lbf and a liner
weight of 175,000 lb (air weight). The pressure to drive the cone in the test is 1900 psi which
generates 226,000 thrust of tension behind the cone. Testing is performed at three different
simulated depths with the precise compression and tensile loading that can be expected at
each connection while downhole:

 Cone at 2450’ from the top of the liner: When the cone is 2450’ from the top of the
liner the compression and tensile loading on the connection ranges from -170,000 to
+231,000 (simulating the connection just above the cone in the pre expanded form and
then just below the cone in the post expanded form)

 Cone at 1250’ from the top of the liner: When the cone is 1250’ from the top of the
liner the compression and tensile loading on the connection ranges from -87,000 to
+314,000 (simulating the connection just above the cone in the pre expanded form and
then just below the cone in the post expanded form)

 Cone at 100’ from the top of the liner: When the cone is 100’ from the top of the liner
the compression and tensile loading on the connection ranges from -7,000 to +394,000
(simulating the connection just above the cone in the pre expanded form and then just
below the cone in the post expanded form)

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Image 1.15: Solid Expandable Systems DLX

Prep Lab

The prep lab is an integral part of our testing and evaluating capabilities. The stations include
areas for:
 Inspection: It is important that the condition of all know test samples meet pre-testing
requirements in order to eliminate any unknowns that may affect the outcome of the
expansion tests

 Make-Up / Break-Out: 3.5” thru 14”

 Welding

 Cone Insertion: This allows us to properly set up the test samples with the expansion
cone pre-inserted into the expandable launcher.

 Ultrasonic Measurement: Ultrasonic measurement allows us to obtain the exact pre-

expansion measurements so that we can account for every distortion in the connection
after expansion. This is critical for understanding thread deformation due to expansion
and leads to better expandable connection design

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Image 1.16 Prep Lab

Prototype Manufacturing

Weatherford finds value in cutting down on prototype manufacturing lead time, keeping
prototype knowledge inside the company, and keeping money inside the company. This is why
Weatherford has invested millions in the most advanced prototype manufacturing equipment
in the industry.

Image 1.17: Prototype Manufacturing

Our prototype manufacturing stations include:

 Handling Tables

 Horizontal Swage

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 Stress Relieve

 Threading

 Inspection

 Magnetic Particle Inspection

 Surface Treatment

Analysis

Weatherford’s connection facility is equipped with a test cellar that safely allows us to burst
and collapse connections after inspection in order to obtain the post expanded pressure
ratings.

The connection facility is also equipped with the Zeiss Coordinate Measuring Machine (CMM)
which allows for pre and post expansion measurements of our expandable connections. These
measurements are used to create an exact computer model of the connection which is then
used for FEA (Finite Element Analysis) purposes.

Image 1.18: Zeiss Coordinate Measuring Machine

Materials Specifications

The specs that cover Solid Expandable Systems practices can be found in the appendix. These
specs outline the special dimensional requirements (or allowable tolerance) of expandable pipe
which go beyond regular API allowances.

Tolerance (or allowable variance from specification) in the wall thickness of a tube is due to
manufacturing precision limitations for seamless pipe. API allows a maximum of -12.5%

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tolerances on nominal wall thickness which is a rather large range. Since API is used as a
standard throughout the oil and gas industry, Weatherford’s specifications require a special call
out in order to obtain tighter tolerance pipe.

For Solid Expandable Systems products, there is a need for more accurate wall thickness control
because the wall thickness directly affects published burst and collapse ratings. So in order to
get the most accurate ratings, we make sure that our pipe is held to a tighter tolerance.

Furthermore, it is easier to predict the amount of compression on our elastomeric sealing

elements when our pipe is held to tighter tolerances. This not only affects the hanging ability
of our elastomers but also the amount of force that is needed to pump or pull the cone through
the expandables.

Image 1.19: Tubular Manufacturing Bench

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The Role of Solid Expandable Systems in Wellbore Operations

Solid Expandable Systems products provide significant value to customers by:

 Improving well architecture

 Mitigating drilling hazards

 Overcoming mature-field challenges

Solid Expandable Systems products provide open-hole and cased-hole solutions using
Weatherford’s MetalSkin® and HOMCO systems.

Open Hole Solutions

Solid Expandable Systems reduce well construction costs and provide additional casing string
while conserving hole size to improve well architecture. Weatherford’s Solid Expandable
Systems products enable the drilling of previously un-drillable wells. Weatherford’s Solid
Expandable Systems products help customers primarily with the four following issues that may
be encountered in the development planning of a well:

 Maximize production string size

 Extend casing string length

 Sidetrack operations

Image 1.20: Applications of Solid Expandable Systems

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Maximize production string:

Open hole liner systems enable maximum return on investment (ROI) and accelerated
production payout by increasing hole size in the target reservoir and upsizing the completion.
This can be achieved even when using the exact same number of casing seats as originally
called for in the basis of design.

Extend casing string:

Through the use of Monobore technology, Weatherford Solid Expandables can effectively add
another casing string with zero loss of hole size. The Monobore system is meant to be run
below 13-3/8” (13 5/8” or 14”) casing, replacing the conventional 11-3/4” casing seat with a
post expanded liner that provides 12-1/4” drift, the same drift as the previous 13-3/8” casing
string. An 11 ¾” liner can be deployed below the Monobore extension if desired or required

Sidetrack operations:

Weatherford’s Open Hole expandables are being used in sidetrack operations on a regular
basis, with a large concentration of the applications happening in the MENA Region. Solid
Expandable Systems is popular in sidetrack operations because:

 Expandables allow the operator sidetrack deeper in existing wellbores, through smaller
casing with the confidence that the target zone will still be reached with optimal hole
size.

 The use of expandables often provide the main economic incentive to performing a
sidetrack operation by allowing the operator to reach target depth with sufficient hole
size needed for adequate Return On Investment (ROI) via the larger completion.

 Expandables provide sufficient ID for larger drill strings in extended reach wells

Weatherford’s Solid Expandable Systems products isolate problematic sections of a wellbore

with minimal loss of hole size. These systems enable temporary isolation of a trouble zone until
section TD is reached and a permanent casing string is installed. Weatherford provides
customers with drilling and completion solutions to mitigate drilling hazards to overcome:

 Pressure Transitions

 Loss circulation zones

 Over-pressured formations

 Shallow flow zones

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 Wellbore instability

Image 1.21: Applications of Solid Expandable Systems

Pressure transitions

Casing strings or liners are required when the pore pressure of the formations being drilled are
approaching the frac gradient or Leak-off at the previous casing shoe. If the inverse occurs
where the frac gradient of the formation being or about to be drilled is less than the pore
pressure of the formations exposed below the previous casing shoe. These can be normal
gradients or abnormal pressure changes. When abnormal pressure transitions occur,
particularly those that are not expected or understood, additional or contingency casing strings
must be deployed. Deploying a conventional casing string or liner will result in a loss of hole
size. The use of expandable liners can be deployed where these pressure transitions are
encountered to minimize the loss of hole size.

Loss circulation zones

Loss circulation zones can occur at any point in the well where mud weight required to control
and exposed formation pressure above exceed the frac gradient of another exposed formation.
This can be caused by naturally occurring formations, depleted reservoirs or abnormal pressure
conditions.

Fighting loss circulation zones can be both costly and risky. “Muscling through” the trouble
zone usually requires extra rig time, adding fluids related cost and increased risks. In more

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severe cases, this type of conventional approach can result in stuck pipe or high casing seats,
which may necessitate a sidetrack or reduced hole size at target depth. In the worst case, this
type of method can result in a loss/kick well-control situation that can compromise the entire
operation.

The second and more proactive set of conventional approaches is well-design based and
involves running additional planned and contingency casing strings and/or liners, which again
increases well construction costs. Additional casing strings also slim the well, which can make it
impossible to reach TD with a completion that is large enough to realize the well's full economic
potential.

Through the use of Weatherford expandables, we can provide a third option, to offer a less
risky option of setting casing across the problematic section still allowing the operator to reach
hole size with optimal casing size. This is because expandables allow for maximum pass
through ID, so even after installation, the basis of design of the completion can be still be
maintained.

Over-pressured formations

Typically pore pressure increases in a normal gradient related to depth and overburden
pressure. However abnormally pressured formation can occur in the well. As pore pressures
increase, the mud weight must be increased to control the pore pressure of the exposed
formations. As this mud weight approaches the fracture gradient of other exposed formations a
casing or liner must be set. An over pressured zone will often require a casing seat prior to
entering the zone as the mud weight required to control the pressure can often exceed the
Leak Off Test (LOT) or fracture gradient of the formations above. The over-pressured formation
can also require a casing seat below the zone to allow reducing the mud weight to drill the
formations below without losses.

At this point, the operator will have to use a contingency string in order to ensure safety of the
operation which will likely put the optimal target depth hole size in jeopardy. However,
through the use of expandables, we are able to set casing above this problem and still get back
to the basis of design.

When formations are more porous than the formations above them, there is a probable
transition into an abnormally, over pressured zone. Detection of this zone is crucial because
casing must be set before excessively high pressured and permeable zones are drilled below.

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Shallow flow zones

Shallow flow zones, much like over-pressured formation can cause drilling risks and should be
isolated.

Shallow flow zones occur when fluid flows from a deep reservoir to more shallow formation,
charging the formation with abnormally high pressures.

There are a number of man-made and naturally occurring causes of shallow flows.

 High pressure from a deeper reservoir can migrate up a fault into a shallow formation

 Wells that are producing but are not properly cemented can serve as a channel for high
pressure formations to leak into shallower formations

 Casing leaks can also cause high pressure formations to be communicated to lower
pressure formations that can affect new wells being drilled

 Improperly abandoned underground blowouts can connect two otherwise impermeable

sections causing the shallower formation to be charged

Wellbore instability

Wellbore instability is a common drilling problem that can result in significant nonproductive
time (NPT) or even loss of a hole section.

The two main reasons for wellbore instability include:

1) Chemically related instability

 Water absorption: One of the most common chemically related instability issues occurs
when water is absorbed from the drilling fluid in shales. This can cause swelling in the
formation that reduces hole size and or alternatively cause hole enlargement when the
formation caves in. This can cause pack off around drilling BHA among other problems
which can cause significant delays to the drilling program. While oil based drilling mud
(OBM) can reduce the effect of this problem, stricter regulatory controls and regional
policies do not always allow for OBM, which still does not completely fix the problem.

 Salt leaching: Another common chemically related instability issue is known as salt
leaching. Salt leaching causes large caverns in the formation and can contaminate
drilling fluid to the point where it must be completely replaced.

2) Mechanically related instability

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 Ductile yield of the rock: This is very common in flowing shales or when drilling through
salt and normally requires multiple under reaming trips in order to get back to gauge
hole size. In more severe cases, ductile yield of rock can cause stuck pipe while running
to target depth.

 Brittle rock fracture: Brittle rock fracture can cause borehole enlargement which is
common in sloughing shales.

 Hydraulic fracturing: Hydraulic fracturing can cause wellbore stability issues as well and
normally causes loss circulation issues which can increase mud costs and could even
result in well control issues.

 Tectonic stresses: stresses build up in formations due to bending or lifting that naturally
occurs over long periods of time. When drilling through tectonically stressed formations
the near wellbore stresses are relieved. The high stresses of the surrounding rock will
act upon the near wellbore causing what is called “Break-out”. The break out normally
occurs perpendicular to the maximum stress direction and can cause severe hole
instability.

Whether it is chemically induced or mechanically induced, wellbore problems can cause

significant challenges to the operator and should be isolated when given the option.

Both the conventional open hole liners as well as the clad are important tools for isolating
unstable wellbore sections.

Cased-Hole Solutions
Weatherford’s Solid Expandable Systems products are designed to overcome mature field
challenges such as; production casing corrosion, casing leaks, isolating depleted perforations,
excessive water production, damaged casing and other issues associated with aging wells.
Weatherford’s systems are a permanent solution that optimizes production capacity for the
customer with these four common concerns:

 Zonal isolation/water shut-off

 Casing splits/parting

 Subsidence remediation

 Corrosion retro-fitting

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Image 1.22: Applications of Solid Expandable Systems

Zonal isolation/water shut-off

Oil is lighter than water and therefore oil sits on top of water in a reservoir. As oil is produced,
the water level will rise to displace the oil. As the oil water contact reaches the level of the
perforations water production will increase, leading to less oil production and increased water
disposal cost. This water can be isolated by setting a MCL expandable liner across the lower
perforations and stopping or significantly reducing the water production allowing for more oil
production and reduced water production and the associated hassles and costs In cases where
selected formations have been depleted and the pressure reduced through years of production
it may be desirable to seal off these perforations to prevent produced fluids from entering the
depleted formation, thereby reducing the wells production.

The MetalSkin® system is a robust liner (or clad) that seals and isolates the perforations.

It bridges the gap in casing repair between cement squeezing and scab liners. The system
provides permanent isolation and eliminates repeated workover operations. Most importantly,
it provides a larger ID and better access than scab liners for future drilling, completion,
production or injection operations.

Furthermore, the MetalSkin® is equipped with “seal joints” that allow for complete zonal
isolation between the section of interest and the rest of the wellbore.

Casing splits/parting

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Casing splits/parting is a common problem and can cause an otherwise successful casing string
to lose integrity.

There a few main reasons why we see casing splits and parting:

 Over torque connections

 Running casing in deviated wells – When running casing in deviated wells the
connections can become bent and cause the threads to slip or come loose, which will
lead to a part in the connection. The added weight of the liner below the bent
connection helps to disengage the box from the pin.

Expandable cased hole systems are designed to provide “casing replacement” and a onetime
permanent fix to such problems. Cement squeezes lack the integrity of an expandable liner and
often break down. Alternatively, conventional liners or scab liners can be run over the split but
the result will be a significantly reduced inside diameter in this localized section, in an
otherwise good casing string.

Subsidence remediation

Above a producing formation, the weight of the overburden settlements is partially supported
by the rock matrix and partially supported by the pressurized fluid in the rock pore space. As
the fluid is able to escape the pores of the rock, the rocks take on more of the load and the
formation is compacted. This phenomenon below the earth can also result in surface
subsidence.

In wells that buckle or shear due to subsidence, expandable cased hole liners can provide a
solution. First the section that is experiencing subsidence will need to be milled and brought
back to gauge hole. Subsidence often leaves an oval shaped casing string and this will need to
be fixed. Second, an alignment tool will need to align the two sections of casing that will
receive the expandable liner. Once the casing has been aligned, the expandable will be run in
the well and expanded across the exposed zone, similarly to a parted casing situation.

Corrosion retro-fitting:

Corrosion is a common problem that is often induced by produced fluids and gases such as;
hydrogen sulfide (H2S), carbon dioxide (CO2) or salt water; however other acids may be present
especially during or after well stimulation.

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Corrosion can cause costly repairs such as replacing equipment, down time due to repairs, and
even possibly abandonment in casing leak situations.

Weatherford’s expandable cased hole liners can prevent having to abandon or pull casing
damaged by corrosion by installing new casing over the problem zone. The new casing allows
for maximum pass through ID, increasing the benefits over conventional liners or straddle
packer solutions.

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Solid Expandable Systems Product Offerings

Solid Expandable Systems products are offered in four different types:

 Open Hole Liners

• METALSKIN® Open Hole Liner

• MetalSkin® Monobore Open Hole Liner

 Open Hole Clads

• MetalSkin® Monobore Open Hole Clad

 Cased Hole Liners

• MetalSkin® Cased Hole Liner

 Cased Hole Patches

• HOMCO products are used as cased hole patches

Solid Expandable Systems Product Naming Guidelines

Products are named based on their purpose served in the well:

 Liner: The expandable ties back and seals into host casing (can be run with or without
cement)

 Clad: The expandable seals against the open hole formation (run without cement)

 Monobore Liners or Clads: The expandable ensures that there is no loss of hole size
between installed expandable and clients host casing

Products are also named according to their application and family product:

 Application

• Cased Hole

• Open Hole

 Family Product

• MetalSkin®

The function and size of solid expandable products also help to better understand the naming
structure:

 Function

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• D0 = Host Casing ID

• D1 = Post Expanded ID

• Liner: D1 < D0

• Monobore: D0 = D1

 Size (Based on OD)

• 5-1/2 x 7  pre expanded liner is 5-1/2”, host casing is 7”

• Post expansion OD is greater the 5-1/2” but less than 7”

Examples:

NOTE: HOMCO is defined by the host casing that the patch seals into.

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Knowledge Confirmation Questions 1.1

1. The process of expanding by means of swaging is…
1. Telescoping
2. Cold working
3. Pass through ID

2. Weatherford uses the following method when expanding

tubulars…
1. Top Down
2. Bottom Up
3. Solid expandables are primarily used in the following operations….
1. Drilling
2. Workover
3. Both

4. When trying to get back to the basis of design (BOD), a client would most likely use
what type of solid expandable system?
1. Open hole
2. Cased hole

5. The maximum allowable defect tolerance in the longitudinal direction of the

tubular
is….
1. 3%
2. 7%
3. 10%

6. FODC-OR connections use a rubber to metal seal or metal to metal seal?

1. Rubber to metal
2. Metal to metal

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7. ______ are utilized on the expandable liner in order to protect the connections while
running downhole.
1. Elastomeric sealing elements
2. Thin wall steel connection sleeves
3. Both

8. What specification states “The expansion test shall reproduce the

conditions experienced downhole” for testing expandable connections that is
currently under development?
1. ISO 13679
2. RP5-EX

9. Weatherford’s capability to test SES connections using our Expansion Benches allows
us to test which of the following parameters?
1. Fixed-Free scenarios
2. Fixed-Fixed scenarios
3. Constant curvature expansion
4. All of the above

10. Weatherford’s expandable tubulars are manufactured to tighter tolerances than

conventional tubulars.
1. True
2. False

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