PoroFlex

Expandable
Completion Systems

Cliff Wohleb Global Advisor

Technology Overview

For External Distribution. 2005 Halliburton. All Rights Reserved. 12 June 2006
 2

Where Does Sand Control Need to

Go? Screen OHGP HRWP Delta Expanded Expanded
Only FracPac Screen Completion

Productivity

Reliable
Sand Control

Operationally
Attractive

Cased Hole
Functionality
Zone Isolation
Pore Pres Cont.

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 3

Introduction to PoroFlex

What it is
Halliburtons expandable completion system
A means of improving sand control completion
functionality
A compliment to our existing sand control technology
portfolio
What it is not
1-for-1 replacement for gravel/frac packing
A difficult to understand technology
Unproven and untried technology

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 4

Why Expandable Screen

Completions?
Cased hole functionality in open hole completions
Larger bore makes OH multi-zone possible
High angle or horizontal wells to increase wellbore
exposure
Maximum reservoir exposure
Maximum flow area
Direct connection to wellbore
Reduced non-Darcy pressure loss
Low skin completions

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 5

Design Requirements

Examining a commonly held belief:

Borehole Compliance Is Required for Sand Control

Investigative Approach:
Failure mode identification for expandable screens
Effects of shale
Effects of water breakthrough
Identifying expandable screen requirements that
address complex reservoir and well conditions
Identify critical design criteria

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 6

Shale Failure Modes

Rugged borehole
conditions from failure
during drilling
shale
Production issues
Mechanical failure during
production
Bedding planes
Chemical incompatibility
Pore pressure variation

sand

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 7

Mechanical Failure Drilling vs.

Production

Drilling: 1ppg overbalance Producing: 520 psi drawdown

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 8

Mechanical Failure
Shale breakouts seen
during drilling operations
Isotropic behavior

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 9

Mechanical Failure

Mechanical failure during production

Production conditions will place higher stress on
shale
Significant failure can occur during production
Effect of failure on mechanical properties
Unlike sand, shale properties change
significantly as a result of failure
Reduced friction angle and cohesion

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 10

Mechanical Failure

Low friction angle in the failed region limits its

ability to support differential stress
Stress will be applied to the screen
Effective or exposed surface area of the failed
shale around the wellbore becomes very large

1 lb < 1 lb 1 lb 1 lb
force force force force
in out in out

Sand angularity Low shale angularity

provides support provides no support

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 11

Bedding Plane Instability

Weak bedding planes

reduce cohesion and 1 PPG
the coefficient of sliding Over Balance
friction. Bottom
Bottom

Introduce directional
permeability barriers
Can lead to anisotropic
failure conditions
520 psi
Increased risk of Drawdown
point loading Bottom
Bottom

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 12

Chemical Incompatibility
Exposure to incompatible fluids
During drilling, completion or work over, or with water
breakthrough
High surface area of failed shale increases
reactivity
Shale swelling applies a load to the screen
Reduction of friction angle increases screen loading
Chemical incompatibility further weakens
bedding planes by reducing the coefficient of
friction.
Risk of point loading due to
Bedding plane slippage
Anisotropic failure conditions

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 13

Stable Arch Theory

Friction angle and
cohesion allow the failed
region to support
significant stress

Screen conformance
is essential
Prevent movement
Create a stable arch

Highly dependent on
Mechanical properties
Screen provides support
to minimize movement
Reservoir conditions
and does not require
Halliburton 2004

strength
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 14

Stable Arch Theory

Assumes that the primary stress planes are
Equal
Perpendicular to borehole axis
Arch stability only exists when variables creating the
arch remain constant
Pore pressure
Drawdown
Local stresses in the rock
The best that can be said is that a meta-stable arch is
created
Halliburton 2004

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 15

What Will Destabilize the Arch?

The presence of exposed shale

Shale
Shale behaves
behaves differently
differently than
than sand
sand
Reduced
Reduced friction
friction angle
angle after
after
failure
failure
Compressive loads are applied
directly to screen
Weak bedding planes can cause
point loading
Chemical effects cause swelling
and weakening
Source
Source for
for massive
massive mobilization
mobilization shale
of
of fines
fines and
and plugging
plugging

Shale will NOT form a stable arch sand

Loads applied directly to screen

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 16

What Will Destabilize the Arch?

What exists is actually a delicate equilibrium
What will happen if water is added?

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 17

Shale: The Origin of Fines for Massive

Plugging
Shale
Shale break
break out
out
Mechanical
Mechanical failure
failure under
under
applied
applied draw
draw down
down
Water
Water breakthrough
breakthrough
shale
Increased
Increased fines
fines mobility
mobility
Shale
Shale swelling &
weakening
weakening

sand

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 18

The Degree of Compliance Required

Depends Upon Individual Screen Properties
Borehole compliance is essential for screens
with little collapse resistance
Strength, required for completion integrity, is derived
from screen/borehole contact
Borehole compliance is not required for higher
strength screens
The degree to which reliable annular isolation can be
achieved is the degree of compliance required

Isolating shale behind blank pipe and annular

barriers will reduce exposure of shale to the
screen, reducing the risk of failure.

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 19

PoroFlex for Reliable Sand

Control

Built on a Strong Foundation

High collapse resistance
Durable and strong filter media
Prevents annular solids transport
Isolate large shale sections behind pipe
Annular barriers must be used
Must provide pore pressure containment under
production conditions
Fixed cone hydraulic expansion

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 20

Base Pipe

High strength solid or near-

solid base pipe
High
High collapse
collapse resistance
resistance
Ability to isolate zones
behind blank pipe
Circular expansion
Maximizes collapse strength
Improved cased hole
functionality

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 21

The Importance of a Circular

Expansion Profile

Ovality = Dmax / Dmin

Collapse strength is
severely
compromised with
Ovality = 1.1 elliptical expansion
~48% loss
X
Ovality = 1.2
~63% loss
X
Halliburton 2004

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 22

Filter Media Construction

Extremely
Extremely rugged and durable filter
media
media
Outer shroud, drainage layers,
and filter media diffusion-bonded
to become a single component
Will maintain integrity, even under
extreme deformation and collapse

Filter layer

Outer shroud

Base Drainage layers

pipe

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 23

Extreme Filter Media Testing

Extreme testing conducted
on PoroFlex screen
Under collapsed
conditions, filter media
remains intact
Filter media has high burst
pressure ratings
Not essential to be in
contact with the
formation
Well kill operations
Stimulation

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 24

Unchanged Screen Rating

Micron rating can change only if warp
(yellow) or weave (red and blue) wire
diameters change sufficiently
Warp wire diameter primarily controls
micron rating
Warp wire oriented along longitudinal
axis of base pipe
Pipe expanded radially
Warp wire diameter (d) unchanged
Weave wire diameter decreases (plastic
yield) due to diffusion bonding
Space between warp wires increases (s
Diameters and distance change drawn to scale
to S)
Flow area increases
Area increase isnt enough to change
micron rating

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 25

Mechanical Annular Flow Barriers

Annular flow must be eliminated

Isolates shale
Prevents progressive plugging
Four configurations are available
Fixed Reach Annular Barrier Tool (ABT-FR)
Fixed Reach Swellable Annular Barrier Tool (ABT-FRS)
Variable Reach Mechanical Annular Barrier Tool (ABT-
VRM)
Variable Reach Chemical Annular Barrier Tool (ABT-
VRC)

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 26

ABT-FR Technology

Fixed Reach ABT

Ideal for gauge or near-gauge
wellbores
Multiple post-expansion ODs
available
Swellable elastomer version
further increases seal
capability

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 27

ABT-VRM Technology

Variable Reach Mechanical

ABT
Maximum diameters
10.5 for 8.500
Conforms to any hole shape
Inert fluid in chambers
prevents formation damage or
fluid contamination
Maintains contact stress
against formation

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 28

ABT-VRC Technology

Variable Reach Chemical

ABT
Sealant bonds to elastomer,
rock, or steel
Note that ABT-VRC module
run uphole from VRM
module
Upper compliant cylinder
diverts chemical sealant
toward toe
Temperature compensation
available

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 29

Variable Expansion

Diameter varies, not the profile

Based on expansion resistance
Closed loop metering system
Allows running through seal bores or tight formation
without round trip
Expanded ID variability from 7.3 to 8.0
Expanded OD variability from 8.0 to 8.8

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 30

Variable Expansion

A B C

OD ID
Location (inches) (inches)

A 8.332 7.820
B 7.700 7.162
C 8.345 7.865

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 31

Key Features PoroFlex

Expandable
Completion

Perforated / solid base pipe

Conforming annular barrier
technology
Premium one-piece diffusion- Well
Productivity
bonded laminate screen
Sand Control
Integral joint expandable threaded Reliability
connection Operationally
Attractive
Hydro-mechanical expansion
Large Internal
Expand blank pipe / screen Diameter
combinations Zone Isolation

Pore Pressure
Halliburton 2003

Containment

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 32

Reliable Sand Control

Small or no annular space

Annular flow barriers
Prevents annular solids transport in complex hole
conditions
High collapse resistance
Durable and strong filter media
Isolate shale sections behind pipe
Annular barriers must be used
Must provide pore pressure containment under
production conditions

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 33

PoroFlex - Delivering PoroFlex

Expandable
Completion
Cased Hole Functionality
Large ID for flow control devices
Circular profile and uniform ID for packer
and flow control applications
Stable well profile for remediation & access Well
Productivity
Zone isolation for flow control Sand Control
Annular flow barriers Reliability
Operationally
Pore pressure containment Attractive
Isolate high pressured shale or water Large Internal
bearing intervals Diameter
Annular pressure containment Zone Isolation
High collapse resistance
Pore Pressure
Halliburton 2003

Containment

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 34

PoroFlex successes - PEMEX

Typical production rates for Veracruz region is 4-8
MMscfd
Papan 2: 200 m of sand, 40 m of shale with water at
bottom
PoroFlex expandable screen at sand, blank pipe
and ABTs used to isolate shale and water
41 MMscfd tested
Papan 93 MLT level 4
Main bore had 250 m of screen, 3 ABTs isolating shale
between two sand zones
Upper lateral: 8 deg/100 m dog leg, 300m screen, 5 ABTs
isolating 3 shale zones
Upper lateral = 47 MMscfd, expecting 100 MMscfd
Halliburton 2004

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