SPE 100747
Expandable Sandface Completions—Design and Performance Review of Single-Zone
Applications and Journey to Next-Generation Multizone Systems
Quentin Morgan, Colin Jones, and Ally Macarthur, Weatherford
Copyright 2006, Society of Petroleum Engineers
This paper was prepared for presentation at the 2006 Abu Dhabi International Petroleum
Exhibition and Conference held in Abu Dhabi, U.A.E., 5–8 November 2006.
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Abstract
The advent of Expandable Sand Screens (ESS) technology
heralded a new era in mechanical downhole sand control by
specifically addressing perceived limitations of standalone
screens (SAS) and complexities of gravel packs. To date, ESS
has been installed in over 400 wells worldwide under a variety
of operating conditions, with the majority in single-zone
environments.
This paper describes designs aspects and applications
engineering behind historical ESS applications, and discloses
findings from a recent survey of these installations to derive
key performance and reliability indices. A discussion of how
these findings have been used to better understand and refine
operations envelope for ESS and improve robustness of
applications engineering to yield greater system reliability is
also included.
The productivity benefits of ESS technology, has been the
subject of several authorative papers, with growing body of
anecdotal evidence now in the public domain quantifying
productivity gains achieved compared with other wells
employing variety of other sand control techniques,
particularly in open-hole environments.
The drive for maximum well productivity compels many
operators to consider openhole completion strategies.
However, this has often not been possible through inability to
achieve effective zonal isolation. Though ESS has been
interfaced successfully with available annular barrier
technologies to satisfy this goal in cased hole, technical
limitations have constrained use in open hole.
This paper documents therefore an 18-month expandable
technology research and development effort that has
culminated in the introduction of a wholly new multi-zone
Expandable Reservoir Completion (ERC) architecture, where
selective isolation or production provides advantage.
This next generation ERC system combines slotted and
solid expandable technology to deliver a reservoir completion
with a combination of openhole production performance and
casedhole functionality. Early results from initial ERC
installations are showcased to illustrate system potential.
Introduction
In recent years there had been few radical developments in
the sand control arena. When the first ESS was launched in
1999 it was not only a radical departure from convention, it
introduced the concept of direct screen contact as a means of
overcoming the limitations of SAS and complexities
surrounding open hole gravel packs (OHGP). The design
premise was that a compliantly expanded filter that could
eliminate the screen-to-wellbore annulus would promote rapid
formation stabilization and minimize the movement of sand
particles around the screen under production conditions,
resulting in reduced erosion and screen plugging. In so doing,
and with the large directly exposed filter surface minimising
pressure drop in the screen, both productivity and reliability
would also be boosted1. The role of the reduction in the
annular gap in increasing completion reliability has been
discussed in Helland et al2
ESS was initially aimed specifically at openhole
applications, with features such as large exposed filter area
and variable ESS borehole contact (becoming known as
compliant expansion) included to provide gravel pack
functionality with the operational simplicity of a stand-alone
screen. However, the applications envelope has over time
extended to encompass cased-hole environments as a
replacement for cased hole gravel packs (CHGP) and cased
hole frac-packs (CHFP).
Previously published papers have discussed the design and
construction of ESS in detail1, but a brief overview of the
concept is discussed here:
4.0” Expandable Sand Screen [ESS]. As shown in Figure 1,
ESS construction comprises three sandwiched layers; the base
pipe, the filter media and outer protective shroud. The base
pipe, unlike all other forms of mechanical downhole sand
exclusion technology, is slotted rather than perforated, as is
the outer shroud. These slots open during expansion to
accommodate the change in diameter, while over-lapped
layers of filter media slide across each other to maintain sand
integrity. The use of slots allows expansion ratios up to 80%
greater than the original diameter and provides a larger inflow
2 SPE 100747
area than perforated pipes. The entire length of the ESS joint
is expanded, including the connectors, which are sand tight yet
allow flow through. This allows flow along the entire ESS
completion without any blank sections.
As the ESS is expanded it eliminates the annulus between
the screen and the borehole. This feature offers a number of
benefits:
• Eliminating the screen/wellbore annulus effectively
liberates an extra casing string in the well design whilst
providing the same or larger production bore.
• Removing one casing string can lead to cost reductions of
up to 20% on the total well costs.
1 EST Base Pipe 2 Woven Filter Matl 3 Outer Shroud
Slots open up Sheets slides over Slots open up
one another
Expandable
UNEXPANDED Base Pipe
Overlapping
Layers of
EXPANDED
Filter Media
Expandable
Outer
Protective
Shroud
No change in
weave aperture
Figure 1 - ESS construction showing cross-section through pre-
shrouded and shrouded ESS
When an expandable screen is expanded to fit tightly in a
wellbore, the ability to manage the reservoir inflow or treat the
reservoir is greatly increased. With the annulus eliminated, it
is possible to set devices within the screen to isolate sections
or to squeeze treatment fluids into the formation. In addition,
results from production logs can be significantly enhanced
because flow from the reservoir enters directly through the
screen and into the wellbore, rather than along the annulus.
A further fundamental benefit of expanding the screen to the
wellbore diameter is the ability to achieve borehole
stabilization characteristics better than a well-placed gravel
pack because it can impart a force into the wellbore face.
Axial Compliant Expansion [ACE] Tool. A diagram of the
ACE tool is shown in Figure 2. The front rollers are fixed and
pre-expand the screens to a set diameter. Hydraulic pressure is
used to activate the middle and rear sections of the tool which
extend out to ensure the screens are compliantly expanded to
fully contact the borehole, even in rugous, tortuous and oval
shaped hole geometries.
Expanding the sand screens to fully contact the borehole
not only affords borehole support, but, by eliminating the
annulus behind, facilitates wide range of mechanical and
chemical intervention solutions for pinpointing and
remediating eventual water breakthrough.
Figure 2 – Axial Compliant Expansion (ACE) Tool
7.0” Liner Hanger/Packer [EXP]. The EXP is a large bore
permanent hanger / packer that has been designed specifically
to be deployed with expandable sand screens. This original
design EXP hanger is set on the first trip in the hole. After
setting the EXP, the running tools are returned to surface, with
a second trip required to expand the screens.
Sand Control Circulating Valve [SCCV]. The SCCV is used
to prevent formation fines or solids from entering the ESS
string while running in hole. It incorporates a one way valve
system which facilitates circulation to the bottom of the
assembly.
ESS Performance
With over 400 ESS installations totaling more than 76km
installed length and cumulative production history exceeding
1000 years, it has become possible to determine whether ESS
does indeed offer the improvements claimed by the designers
and to formulate selection criteria for their use. Jones et al
have conducted an extensive survey to quantify performance
of these ESS completions, analyse failure mechanisms and
causes and derive estimates of long-term reliability3.
There have also been a large number of case studies
published which have looked at ESS performance, in a wide
variety of well types, vertical, horizontal, gas, gas-condensate,
water and oil wells. The current maximum fluid production
rate is 25000bpd, the maximum gas rate is 290MMscf/d, and
the maximum water injection rate is 40000bwpd, with a recent
record installed length of 4274ft established for 5.5” ESS, and
longest installation record set in 2001 at 7000ft using 4” ESS.
Weekse et al4 documented the installation and performance
of 3 long horizontal gas wells in the Brigantine field, in the
Southern North Sea. The wells had up to 40% improved
production beyond expectation. They were completed 32days
ahead of schedule with a saving of $13.5M. These wells have
been producing for over 4 ½ years.
The performance of the ESS completed wells in the gas
condensate Scoter Field was also very good, with no evidence
of formation damage5. These wells have been producing for
over 2 years.
SPE 100747 3

The Xijang Field in China is a mature field with high water limiting formation movement and yield. This could
cut. ESS was installed in a number of wells, including a theoretically lead to a slightly lower skin16. Filtercake cleanup
multilateral6. Each lateral produced 2-3 times more production and mixing with failed formation material will also have a
than alternative fracpack and gravel pack sand control large role.
completions used previously. Figure 4 shows the openhole skin values broken down for
Due to its small running outside diameter and large final vertical (<15°), deviated (>15° & <85°) and horizontal (>85°).
internal diameter (ID) ESS is particularly applicable to The data shows no negative bias towards the deviated and
situations where reductions in final ID must be avoided, such horizontal wells, which suggests that the skins are in fact true
as in workovers and sidetracks. Oluwatosin et al7 show that formation/completion skins.
ESS completed sidetracks produced between 60-99% more
than the prognosed rates. 15.00
Openhole Customer Skin Data Analysis
40
There have been many others, which have noted increased
Data Wells
production and a reduction in costs8,9,10,11. ESS has also been All OH Skins
used as replacements for multzone CHGP12. There have also 10.00 30

been theoretical papers aimed at demonstrating the benefits of

# Data Wells
Skin Value
large ESS ID in improving sweep efficiency and recovery 5.00 20
factor of a reservoir13.
All the references cited above have looked at the
0.00 10
performance of the ESS completed wells shortly after
installation. Typically a well test will be performed just after
completion to determine the wells performance and to check if -5.00 -

All Horizontal
All OH Deviated

Horizontal
Cone Deviated
Cone Straight

Horizontal
Compliant

Compliant

Compliant
straight(<15)

Deviated
Straight
any further clean up or stimulation is needed for the well to

Cone
All OH

achieve its potential. A number of operators have shared the
skin values determined from the well tests. Data is available
on 98 wells; some of this data has already been published14.
Figure 3 shows an updated compilation of the openhole
skin values. Although we have no control on how the skins are
calculated, we have been assured that they are
formation/completion skin values as defined by Van
Everdingen and Hurst15, the effect of deviation and horizontal
wells has been removed. The data shows that for the openhole
wells there is an average skin of 0.9. This is a very low value
and compares favourably with other openhole sand control
completions.
Customer Supplied Openhole Skin Data
40
# Cone OH Skin
35
# Compliant OH Skin
30
25
# of skins
(>85)
(<85)
Figure 4 - Openhole skins for vertical, deviated and horizontal
wells
ESS completed wells have now been producing for close
to 6 years. Case studies are now being published looking at
long-term performance (Mason et al17, 19). This case study
analysed the long-term performance of an installation dating
back to Q4 2000, which has close to 6 years of production
history. The ESS was compared to a SAS and an OHGP. The
ESS had much higher productivity and lower skin. Also the
ESS appeared to maintain a low skin over the study period,
whereas the SAS became rapidly impaired. The OHGP also
declined but to a lesser extent. Normally in a sand prone
environment electrical submersible pumps (ESP) need

20 changing regularly, but the well with ESS has had the same
ESP for more than 4 years. This is a strong testament to the
15
long-term sand integrity of the ESS.
10
To summerise the production performance of the ESS the
5 published data shows that the ESS results in low completion
0 skin and thus high productivity, and can sustain this
>-1

>0

>1

>2

>3

>4

>5

>6

>7

>8

>9

productivity over time. Where comparisons are made, the ESS

Skin Value (Range)
Figure 3 - Compilation of Openhole Skin Values for Compliant and
Non-compliant ESS
There is as interesting split between systems expanded
with a fixed cone, which will not be fully compliant, and
systems expanded with a compliant expander, which will be
fully compliant. The non-compliantly expanded systems
exhibit an average skin of 2.5 whereas the fully compliant
applications exhibit an average skin of 0.3. This distinction
sharply contrasts the performance benefits of compliant
expansion. It is thought the reason for this contrast will be due
to compliantly expanded ESS stabilizing the formation and
is much better than the alternative sand control completion
option.
However production performance is not the only selection
criteria used in choosing the type of sand control to fit to a
well.
Sand-Face Completion Design Aspects
For each and every ESS candidate well, it is imperative first
and foremost to assess ability of these technologies to provide
long-term sand retention integrity. Only when this has been
confirmed through extensive applications engineering is it
relevant to then study and quantify productivity gains and
other technical and commercial benefits. Verifying suitability
4 SPE 100747
of open hole sand control systems requires detailed review of
formation sand sieve analyses, fluid chemistry, production
conditions and well data.
Sand sieve analyses are used to derive recommendations
for weave size and assess plugging potential. Corrosion
potential is quantified from analyses of fluid chemistry and
production conditions, culminating in metallurgy
recommendations to mitigate sand retention and mechanical
failures. Erosion is not generally an issue in open hole
environments owing to the large in-flow area, however it will
be necessary to review rock properties to ensure the ESS
Screens can withstand collapse stresses induced by reservoir
drawdown and depletion.
It will also be necessary to consider impact of well
trajectory on ability to deploy the sand-face completion
without risking helical buckling or exceeding the maximum
permissible dogleg severity and ensure there will be sufficient
slack-off weight available to expand the sand-face completion.
The chemical formulation of the Drill-In-Fluid (DIF) will
also need to be reviewed and an assessment made of the
screen plugging potential during deployment and ability to lift
off and flow-back the filtercake during subsequent well clean-
up operations.
ESS Weave Size Selection. Various Hollander twill woven
wire weaves are available for use with ESS. Selecting the
appropriate weave size for controlling sand production is a
critical part of the sand-face completion design process. For
open hole applications the sizing criterion developed by
Ballard & Beare18 based on the largest 5% of sand grain
distributions is used.
Geomechanical Modeling. Owing to the modest collapse
strength of slotted ESS, the use of this technology in open hole
environments requires careful analysis to ensure an open
production channel is maintained throughout well life under
anticipated changes in rock stresses arising from reservoir
drawdown and depletion.
Contrary to common perception, the ability to withstand
such stresses is dictated predominantly by rock friction angle
rather than either rock strength or ESS strength, with slotted
ESS proven by experiment to withstand collapse pressures in
excess of 10,000 psi in even highly unconsolidated rocks.
Metallurgy Selection. ESS metallurgy has to be thoroughly
researched to ensure compatibility with prevailing in-situ
reservoir conditions and fluid chemistries, including potential
treatment and stimulation cocktails that might be employed at
any stage during well life. In particular, the Hollander twill
weave has a large surface area and low cross-section, and thus
cannot be allowed to suffer any material loss through
corrosion as this could quickly alter and ultimately
compromise sand retention integrity.
Erosion Potential. Extensive erosion tests of Hollander twill
weave in accordance with Southwest Research Institute
(SwRI) erosion protocols led to development of a velocity
threshold criterion to ensure sand impingement does not
compromise sand retention integrity. In long open hole
horizontal oil wells, fluid velocities will generally be
significantly less than this threshold velocity.
Filtercake Flow-Back Tests. A common concern with all
forms of downhole sand control in open hole environments,
particularly in long reach horizontal well applications, is the
potential difficulty experienced lifting off the mud filtercake
and potential for this to plug the screens. With fully compliant
ESS screens, the expansion process crushes the filter cake, and
so aids filtercake removal. The filtercake nonetheless must
pass directly through the Hollander weave sand filter.
However, extensive laboratory tests and field experience
suggest that filtercake flow back is not a common problem,
with an extensive database compiled of laboratory flow-back
tests of different filtercakes.
Mud Flow-Through Tests. Proper selection and design of the
drill-in fluid has a major impact on overall success of any
horizontal open hole drilling and completion program. A
properly engineered mud system should be able to drill a near
gauge hole, limit fluid loss, create a thin tight filter cake and
have optimum rheology for hole cleaning. In wells requiring
downhole mechanical sand control, the particle sizes of
additives used could lead to plugging of the screens if not
properly conditioned. The alternative is to swap out to a
solids-free mud system prior to running the sand-face
completion.
Expandable Reservoir Completion System Concept
and Configuration
From the extensive experience gained from the 400+ ESS
installations to date, the base ESS technology platforms are
now being integrated with new and conventional downhole
technologies in a move to evolve the original, single zone
reservoir system into a suite of solutions aligned with
Operators’ increasing preference to unlock the potential
afforded by migrating to a multi-zone reservoir completion
strategy.
The most common conventional approach employed to
provide zonal isolation in unconsolidated formations is to set
and cement casing in the wellbore to isolate between zones.
The casing is then perforated prior to the installation of a
screen and placing gravel to control solids migration. This
technique has worked reasonably well but has a history of
producing high skin values and, with the advent of long,
horizontal completions, has often been found problematic and
expensive to implement.
In 2004-05 Weatherford have developed an expandable
system that addresses these limitations by providing maximum
wellbore productivity while negating the requirement for
cementing and perforating; an openhole ESS installation with
integrated solid expandable zonal isolation joints between
zones.
Figure 5 shows a schematic of the ERC design concept.
The stated mission of the development project was to “Deliver
a widely applied completion technology, with sand control
effectiveness and installation efficiency better than
conventional; productivity better than open hole; operability
better than cased hole”. The project mission stated the
following goals:
SPE 100747
• Compliant Sand Control [and associated productivity
benefits]
• Zonal Isolation Capabilities
• Fluid Loss Control Capability
• Full Compatibility with Selective / Intelligent Upper
Completions
• Single Trip Installation
These goals, alongside the operator’s technical
requirements, drove the functional specifications that
constrained the product development. Table 1 details some of
the high-level system functional specifications.
System Functional Specifications
Number of Trips to Install One
Expansion Mechanism Compliant
Target Reservoir Hole Size 8.50”
Minimum Compliant Range 9.25”
Selective Upper Completion Compatibility Full
Sand Exclusion Functional Specification
Type ESS®
Hydraulic Collapse 250psi
Zonal Isolation Functional Specification
Type Solid Expandables
Target Differential Rating 3000psi
Table 1. Multi-zone ESS System Functional Specifications
Development of the Expandable Reservoir Completion
required involvement of the entire product, manufacturing and
operations expertise and know-how that Weatherford have
created over the last 8 years, in both slotted and solid
expanded tubulars, as well as intellectual property.
The resultant system is an evolution of existing ESS
technology and incorporates compliant expanded solid tubing
to provide zonal isolation capability. When providing a sand-
face completion with reservoir zonal isolation functionality, it
is imperative that the system is able to fully backwards
integrate with conventional upper completion components, in
order to provide selective production and isolation
capabilities.
Operationally, it was recognized that this next generation
system must have the ability to be deployed and expanded in a
single trip. This is an important feature for higher cost well
environments where trip time is an expensive commodity.
Fulfilling these various objectives culminated in the
following system components:
Expandable Sand Screen [ESS]. A new size of ESS,
incorporating a 7.0”, 29ppf base pipe, has been created as part
of the system development (Figure 6). The 7.0” platform
enables a greater compliant range to ensure compliance in hole
sizes in excess of 9.0”. The thicker wall section and optimized
slot pattern also makes the new product more robust.
Unlike the original ESS® design, the basepipe is not
slotted along its entire length; solid pipe remains at the joints
ends, to allow for non-expandable premium couplings.
Unexpanded premium couplings underline the robust nature of
5
the new product and are common to all system components,
promoting modularity.
The transition between the non-expanded and expanded
section includes solid plates behind the weave to prevent
potential erosion over the non-compliant length.
Expandable Zonal Isolation [EZI]. The key to
Weatherford’s new Expandable Reservoir Completion System
is the Expandable Zonal Isolation [EZI] device, which utilises
proprietary rotary compliant expansion technique to clad the
formation wall, effecting openhole zonal isolation.
Solid expandable technology has been used extensively to
address zonal isolation challenges in the wellbore and has
been applied in both cased and openhole scenarios. In order to
provide effective isolation an elastomeric compound is bonded
to the outside diameter of the pipe. When the pipe is expanded
to contact the wellbore inside diameter, the elastomer is
compressed between the formation and the solid pipe,
providing a hydraulic seal.
Unlike casedholes, drilled openholes are seldom gauge or
guaranteed to fall within predetermined tolerances. Therefore
in order to provide a competent seal, the zonal isolation device
must have the ability to accommodate variable borehole
diameters and non-circular cross sections. The EZI unit is
activated using compliant rotary expansion tool. The tool
delivers a compliant range of geometries designed to operate
and effect a seal in openhole conditions.
The expandable section of the EZI unit features an
extended section of moulded, ribbed elastomer with solid end
back-up (Figure 7). The elastomers are protected during
deployment using cross coupling centralisers and a mechanical
tag is located within the expandable section for positive depth
correlation during expansion operation. As with all of the
expandable reservoir system components, the connections are
non-expanded premium couplings.
Conventional Unexpanded Casing. The expandable
reservoir completion system is modular by design and can
include lengths of Oil Country Tubular Goods (OCTG) casing
between ESS and EZI joints. The casing is not designed to be
expanded, but is used to space out the completion across the
reservoir section – resulting in maximum completion design
flexibility.
Including standard OCTG unexpanded pipe in the string
provides reference points for integration with conventional
inner string completions including ICT. This high level of
integration with conventional technology is the hallmark of a
mature technology offering.
ERC Expansion System. Both the ESS and EZI are expanded
using proprietary rotary compliant expansion technology. The
ESS and EZI require slightly different tool designs. The ESS
has a larger % expansion requirement with reduced force,
whereas the EZI requires less % expansion, but higher
expansion forces. For this reason 2 different expansion tools
are required in the string. The ESS Expansion Tool is situated
at the bottom of the string and incorporates 2 rows of 3 piston-
mounted rollers. The EZI tool is situated above the ESS® tool
and has 1 row of piston-mounted rollers.
6 SPE 100747
Diverter Tool. Selecting the appropriate expansion tool for
the zone requires a Diverter Tool to be incorporated in the
string between the 2 tools. The Diverter Tool simply switches
between the ESS and EZI tools using flowrate and associated
backpressure.
EXR Liner Hanger + SAT Running Tool. These
components deliver one-trip, expandable reservoir completion
installation. The EXR Liner Hanger/Packer is an evolution of
the two-trip EXP Hanger/Packer. The SAT tool is a fully
hydraulic running tool which features running and setting keys
that collapse on completion of the hanger setting process
allowing the tool string to be moved through the hanger and
expansion of the ESS / EZI to take place.
Fluid Loss Valve [FLV]. The FLV incorporates a flapper
arrangement which prevents fluid loss to the formation when
completing a well, and allows for testing/setting upper
completion components. A shifting tool in the expansion
string activates the flapper, isolating the reservoir from
wellbore fluid and pressure above, following the expansion
process. Wellbore pressure is then used to open the valve
following installation of the upper completion, and prior to
bringing the well onto production.
In its open state, the curved flapper is fully enclosed within
the wall of the completion resulting in zero flowing restriction
following release for production.
Conclusion
ESS technology has amassed a substantial track record
encompassing many different open and cased hole single-zone
and some multi-zone applications. An extensive survey of
these installations has enabled key performance and reliability
data to be established, which in turn has been used to delineate
the applications envelope for ESS. Furthermore, sufficient
time has lapsed since commercial launch to also project long
term performance. This complete understanding of system
capabilities in conjunction with global uptake denotes a shift
in industry perspective towards widespread acceptance of ESS
as a traditional rather than new form of sand control, offering
unequivocal productivity benefits without the drawbacks of
SAS and complexities of OHGP.
However, it is recognized that limitations of the
technology have constrained uptake for multi-zone open hole
applications, while at the same time, there is a growing
industry trend to migrate towards open hole completion
strategies to unlock field productivity potential. Now, through
the development of ERC technology, combining field-proven
slotted and solid expandable technology, all the zonal isolation
benefits of a cased and perforated completion are available
with openhole productivity performance.
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SPE 100747 7

16. Jones C., Tollefsen M, Somerville J.M. and Hutcheon R. “The

Prediction of Skin in Openhole Sand Control Completions,”
paper SPE 94527 presentation at the SPE 6th European
Formation Damage Conference, Scheveningen, The
Netherlands, 25-27 May 2005.
17. Mason D., Ramos M. J., Pena C. M., Cameron J. and Jones, C.,
“A comparison of the Performance of Recent Sand Control
Completions in the Mokoko Abana Field Offshore Cameroon”,
paper SPE 94651 presented at the 6th SPE European Formation
Damage Conference, The Netherlands, May 2005
18. Ballard T. and Beare S. “Media Sizing for Premium Sand
Screens: Dutch Twill Weaves”, paper SPE 82244 presented at
the SPE European Formation Damage Conference, The Hague,
The Netherlands, 13-14 May 2003.
19. Mason D., Evans M., Ekamaba B., Jones, C. and Cameron J.,
“The Long Term Performance of Sand Control Completions in
the Mokoko-Abana Field, Cameroon”, paper OTC 17809,
presented at Offshore Technology Conference, Houston, May
2006
8 SPE 100747

Figure 5. The Next Generation of Expandable Completion Systems is designed to be applied to multizone reservoirs that are
conventionally completed cased hole. The Expandable Reservoir Completion [ERC] combines ESS® across producing intervals, Solid
Expandable pipe between zones for isolation, and conventional casing to space the components across the reservoir.

Figure 6. A new size of ESS® was developed specifically for Figure 7. Zonal Ioslation is achieved through application of
this joint development project. The 7.0” ESS joint uses the Solid Expandable technology
same base technology but expandable connections were
replaced with conventional premium, unexpanded couplings.