C R E A T I N G

V A L U E

APEX Big Bore Completion Solutions

Value-Adding Solutions From The Application Experience Leaders

 APEX Big Bore Solutions Put You on Top Of The
Value Chain
Big choices create big values for big bores
Completions that use 6-5/8 in. or larger production tubulars can significantly
reduce both operating and capital expenses and increase the net present value of
hydrocarbon assets. However, all big bore completions are not created equal. That’s
why value seekers come to Baker Oil Tools. Baker is the leader in worldwide big-
bore application experience. We’ve applied the lessons learned from that experience
to develop APEXTM Big Bore Solutions - a classification system and multi-level
series of completion systems designed to ensure fit-for-purpose solutions for all
your big bore application needs.

The APEX Classification System:

Function over form lowers risk
and cost
The APEX system classifies various big
bore completion schemes with respect
to functionality and assessment of risk
and reward. APEX completion levels
are differentiated by the location and
types of seals used in the upper and
lower (reservoir face) completions and
the type of isolation that results. So you
can choose the best completion solu-
������� ������� tion for lowering both risk and overall
project cost.

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The APEX Big Bore Classification System helps you choose the best completion level and
design to match your isolation needs - and lower risk and cost.
APplication EXperience Leader

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About the APEX levels
APEX 1 and 2 - Wellbore construction
completions
• Objective - reservoir-face comple-
tions that take place during the
drilling process
• Constraints - based on liner top
load analysis and the operator’s
completion philosophy
• Benefit - operational simplicity
• Costs/risks - completing in a drill-
ing environment
• Risk reduction - contingency avail-
able to convert to an APEX 3 or 4
completion
Experience and choices add value at
all levels
Only Baker Oil Tools supplies the
breadth and depth of products and
application experience in both wellbore
construction and completions to be able
to provide single-source, integrated
solutions for all levels of big bore com-
pletions. Baker combines its applica-
tion experience, innovative processes,
and best-in-class products - including
fit-for-purpose systems - to reduce risk
and increase overall completion reli-
ability and value at all APEX classifica-
tion levels.

APEX 3 and 4 - Isolation completions

• Objective - upper completion that
protects and/or repairs the lower
reservoir-face completion
• Constraints - based on trapped
volume analysis and operator
completion philosophy
• Benefit - additional well protection
• Costs/risks - installation of addi-
tional components
• Risk reduction - use of single-
source, fully integrated completion
components

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 APEX Big Bore Completion Solutions
Application Experience Leaders, Best-in-Class Products
APEX Level 1: Cemented Completion
Objective: Liner top completion
Completion: Cemented liner tied back to surface
Applications: Monobore, cemented liner, remote location
Experience: Colombia, United Kingdom
Description: In this most basic of completions, the liner is run,
hung and cemented. Another trip is made to clean
and polish the polished bore receptacle (PBR). The
integrity of the liner top can then be tested by a vari-
ety of means. If the integrity test fails, subsequent
remedial cementing may be required, or the scheme
can be converted to an APEX Level 3, using a liner
top isolation packer. After a successful integrity
test, the completion string, consisting of subsurface
safety valve and seal assembly, are run in the well
and the seals are stabbed into the PBR.

T-Series™ Subsurface Safety Valve

• Baker's patented radial punch communication
system prevents premature lock-open

BYPASS COMPARISON
(TO SCALE)
FLOW AREA IN WHITE

Liner Tieback Seal Mandrel with

Bullet and/or Completion Seals
• Optional rugged “bullet” seals increase
reliability of APEX Level 1 & 2 com-
pletions

• Non-elastomeric, interference, bi-

directional, severe service seal
designed to reduce risks of damage Conventional Hydraulic Hanger
during stab-in

SDD™ Hydraulic Set Liner Hanger

• Robust solid-body design allows use
at high torque and RPM with total
protection from slip damage

• Quality bypass allows high circulation

rates and removal of larger cuttings
without packing off

SDD Hydraulic Hanger

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APEX Level 2: Integral Packer Completion
Objective: Reduce total time to drill and complete a well
Completion: Cemented liner with integral isolation packer
Applications: Monobore, cemented liner, horizontal/extended reach,
harsh environments
Experience: East coast of Canada, Mexico, United Kingdom
Description: As with APEX Level 1, the completion occurs
during the drilling process. Two options are available
for completion liner cementation: (1) conventional
cementation, as described in the APEX Level 1 com-
pletion; or (2) inner string cementation. In either case,
after cementation, the integral liner packer is weight-
set, using the drill pipe. An integrity test can then
be performed and the completion assembly run and
tested.

T-Series™ Subsurface Safety Valve

• Over 400 7" SSSV installed

UNI-FLEX PRO™ Integral Packer/Hanger

• Optional Uni-Flex Pro packer/hanger increases reli-
ability of APEX Level 2 completions

• Integral ZXP packer/Flex-Lock hanger built on a

single body without any internal connections

• Qualified to proposed ISO 14310 grade VO for packers

FLEX-LOCK® Liner Hanger ZXP™ Liner Packer

• Flex-Lock slips reduce risk associated with hang- • Patented ZX™ Zero-Extrusion Seal Element elimi-
ing heavier loads of APEX liners nates swab-off resulting from high circulation rates
required in big-bore cemented liner jobs
• Patented Flex-Lock slip design distributes liner
load circumferentially, reducing risks of casing
punch-out and body collapse

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 APEX Big Bore Completion Solutions
Application Experience Leaders, Best-in-Class Products
APEX Level 3: Isolation Completion
Objective: Isolate leaking liner top or protect liner top
Completion: Liner top isolation with hydraulic set packer
Applications: Monobore, cemented liner, horizontal/extended
reach, deepwater, remote location
Experience: Colombia, Norway, United Kingdom
Description: A PBR, hydraulic set packer, landing nipple, and
tieback stem are run and located in the top of
the liner PBR. A blanking plug is run and set in
the landing nipple so applied pressure can set the
packer. After packer setting, the plug is retrieved
and an integrity test performed.

Slimline™ T-Series Safety Valve

• Makes it possible to use a 7 in. tubing
valve in 9-5/8 in. casing

• Slimline curved flapper enables

higher production rates from
smaller casing sizes in all
APEX levels

Retrievable PBR
• Optional PBR and seals provide option to float seals and reduce induced tubing stresses

• When run with hydraulic set packer, production seals need not leave the PBR during installation

SABL™ Hydraulic Set Packer

• No body movement eases installation and space-out

• Proven and tested to "gas tight" ISO 14310 VO Specification

• Low casing stress, high load slip element slip system

SUR-SET™ Locking System

• Patented Sur-Set plugs unload
no-go after setting to eliminate
no-go swaging

Flex-Lock Liner Hanger

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APEX Level 3: Isolation Completion
Objective: Protect cemented liner top
Completion: Liner top isolation with compression-set packer
Applications: Monobore, cemented liner, HP/HT, horizontal/
extended reach
Experience: Qatar, East coast of Canada, Oman, Australia, Egypt
Description: After an APEX Level 1 completion is installed, a
Double-Grip JMZX™ Liner Tieback Packer with a
special Snap-In/Snap-Out Shear Release (SISOSR)
S™ Liner Setting Sleeve is run, stabbed into the
existing liner top, and set with compression of the
drillpipe. On the final trip, a completion-type SISOSR
Anchor Seal Assembly is run on the completion
string, along with the safety valve. After the necessary
space-out is determined using the Snap-In/Snap-Out
feature, the tubing is landed and the seal assembly is
anchored in place. No rotation is required during this
completion process. The seal assembly can be fur-
nished with rotational and/or shear release, for redun-
dant methods of retrieving the tubing, should the well
require workover.

T-Series Safety Valve

• Rating envelope predicts valves
performance which can be critical
in higher load APEX completions

Double-Grip JMZX Liner Tieback Packer SISOSR Snap-In/Snap-Out Seal Assembly

• Proven, one-trip, set-on-the-production-string • Provides ability to space out tubing prior to
tieback packer completion system that improves locking seals in place
rig time savings for APEX 3 and 4 completions
• Rotational and/or straight-pull release options
• Weight-set production packer requires no plugging
of tubing to set

• Uses proven “ZX” and Flex-Lock slip technologies

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 APEX Big Bore Completion Solutions
Application Experience Leaders, Best-in-Class Products
APEX Level 4: Dual Isolation Completion
Objective: Liner top completion
Completion: Dual isolation across cemented liner
Applications: Monobore, cemented liner, HP/HT, horizontal/
extended reach
Experience: Indonesia, Australia, East coast of Canada
Description: After an APEX Level 3 completion is installed, a
Double-Grip JMZX™ Liner Tieback Packer with a
special Snap-In/Snap-Out Shear Release (SISOSR)
S™ Liner Setting Sleeve is run, stabbed into the
existing liner top, and set with compression of the
drillpipe. On the final trip, a completion-type SISOSR
Anchor Seal Assembly is run on the completion
string, along with the safety valve. After the necessary
space-out is determined using the Snap-In/Snap-Out
feature, the tubing is landed and the seal assembly is
anchored in place. No rotation is required during this
completion process. The seal assembly can be fur-
nished with rotational and/or shear release, for redun-
Conventional NPT
Connection
dant methods of retrieving the tubing, should the well
require workover.

UniFlex Pro or Flex-Lock Liner

T-Series Safety Valve
• Patented Control Line Jam Nut
System reduces the number of
leak paths at the critical point
where the control line connects to
the safety valve
Hanger w/ ZXP Liner Packer
• Flex-Lock slips reduce risk
associated with heavier loads of
APEX liners
• Patented ZX Zero Extrusion
Seal Element eliminates swab-
off resulting from higher
circulation rates required in
APEX applications

Double-Grip JMZX Liner Tieback Packer

• Proven, one-trip, set-on-the-production-
string tieback packer completion system
that improves rig time savings for APEX 3
and 4 completions

• Weight-set production packer requires no

plugging of tubing to set

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 APEX Level 4: Dual Isolation Completion
Objective: Minimize completion time associated with lower
completion isolation
Completion: Dual isolation with remotely actuated upper packer
Applications: Monobore, deepwater, cemented liner, HP/HT,
interventionless
Experience: Philippines
Description: After an APEX 2 completion is installed, a PBR,
SB-3H Interventionless Hydrostatically Set
Packer, landing nipple, and tieback stem are run
and located in the top of the liner PBR. Apply-
ing pressure to a rupture disk allows the packer
to hydrostatically set. Days of rig time are saved
using remotely actuated packers.

UniFlex Pro or Flex-Lock Liner

Hanger w/ ZXP Liner Packer Slimline™ T-Series Safety Valve

Optional Retrievable Polished Bore Receptacle

SB-3H™ Remotely Actuated Packer SABL™ Hydraulic Set Packer

• Hydrostatic setting requires no plugging
of the tubing to set ����������������
• Space-out is simplified since no move-
ment is used to set packer

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• Brings new levels of rig time savings to
APEX Levels 3 and 4
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APEX Level 4: Dual Isolation Completion

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Objective: Lower completion isolation
Completion: Dual isolation with hydraulic
set upper packer ����� � �����
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Applications: Monobore, deepwater, HP/HT,
horizontal/extended reach, PERFORMTM rating
cemented liner, open and cased hole gravel packs envelope predicts packers
performance which can be
Experience: Norway, Myanmar, Holland, United Kingdom, critical in higher load APEX
Denmark, China, Peru completions
Description: After an APEX 2 completion is installed, a PBR,
hydraulic set packer, landing nipple, and tieback
stem are run and located in the top of the liner
PBR. A blanking plug is then run and set in the
landing nipple so applied pressure can set the
packer. After packer setting, the plug is retrieved
and an integrity test performed.

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 APEX Big Bore Completion Solutions
Application Experience Leaders, Best-in-Class Products
APEX Level 4: Dual Isolation Completion
Objective: Control production of sand, minimize water cut, and
maximize recovery with a minimum number of wells
Completion: Use large gas cap to produce from a thin oil rim.
Wells must be geosteered to 3 ft above the oil/water
contact to minimize risk of gas coning. Subsequently,
the water cut is very sensitive to friction pressures
and drilling accuracy.
Applications: Monobore, cemented liner, open and cased hole
gravel pack, intelligent well with feedthrough tech-
nology, multi-zone production
Experience: Norway
Description: To enhance production rates, a unique natural gas lift
completion is installed above the horizontal section of
each well. This upper completion requires the design
of special, fit-for-purpose production packers and
PBRs with feedthroughs. A short cased-hole gravel
pack is installed across the gas cap using an H2O-
FRAQ™ treatment in combination with 8-5/8 in.
blank pipe and a 7-5/8 in. EXCLUDER™ Extended
Longevity Well Screen. This allows for a 7 in. tubing
string to be stabbed through the upper completion,
leaving a 5.75 in. ID through the lower zone. A com-
bination of ZXP Liner Top Packers and Flex-Lock
Liner Hangers meets the large ID requirements.

Slimline™ T-Series Safety Valve

Retrievable Polished Bore Receptacle with Feedthru's

EXCLUDER 2000™
• Unique extened-longevity screen con-
sists of outer vector shroud, vector
weave filtration membrane, and pat-
ented Bakerweld® inner jacket
• New swaging process improves strength
and corrosion resistance while reducing
its outside diameter
EQUALIZER™ Screen
• Optimizes production and delays water or gas coning in
long, low draw-down, high-rate horizontal wells
• Consists of extended-longevity wellscreen with unique
inflow control device
• First to successfully create uniform production profile
along entire length of horizontal wellbore

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Flex-Lock Liner Hanger with ZXP Packer
APEX Big Bore Completion Solutions
Baker Oil Tools understands that operators run big bore completions
to maximize production. The APEX system leverages our application
experience, best-in-class products, rigtime-saving processes, and
proven technology to do just that at every step of the completion
process.

Reduce Construction Costs, Maximize Production

Baker Oil Tools supplied the industry with the first tubing-retrievable
safety valve to offer full-opening production in smaller casing sizes.
As a result, operators can optimize casing size and production rates.

Baker Oil Tools pioneered the one-trip, cement-circulate-to-

completion-fluid completion. This innovative wellbore construction/
completion process uses a combination of inner string cementing and
ZX seal technology to eliminate liner top testing and clean-up trips,
saving days of rig time.

Delay Coning, Maximize Production

From Alpha to the Beta, Baker Oil Tools is the industry’s application
experience leader in sand control. We were the first to offer a
completion system using the Equalizer reservoir drainage system
to reduce the number of wells and maximize production by
creating a uniform production profile along the entire length of the
wellbore. Baker leads the pack by using the knowledge gained from
multiple simulation tests enabling us to perform world-record-setting
horizontal completions.

Reduce Installation Costs, Maximize Production

Baker Oil Tools pioneered the one-trip, no-intervention-to-set
completion. These completions use a fit-for-purpose packer that
requires no plugging of the tubing to set, thus eliminating time, costs
and associated risks.
To match your completion philosophy, Baker provides two different
options:
1) A standard JMZX Liner Tieback packer can be configured for
one-trip setting on the production tubing.
2) A standard “S” type hydraulic set packer can be converted for
remote actuation by adding a Striker Hydrostatic Setting Module
and an EDGE / Rupture Disc Activation Module.

Both of these completion techniques have been proven around the

world in a variety of big bore, extended reach, deepwater and HP/HT
applications.

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 APEX Big Bore Completion Solutions
Bring your big bore operations to the
top of the value chain.
The strength of a chain is determined
by its weakest link. Big bore comple-
tion leaders prefer Baker Oil Tools for
the unmatched strength that links appli-
cation experience, products, processes,
and technology - and for the resulting
fit-for-purpose completion designs that
improve asset value. For more informa-
tion on getting top value from your big
bore completions, contact your local
Baker representative today, or visit
www.bigborewells.com.

Baker Oil Tools. THE Completion Company.

08/01 8M
Pub. No. 20002843
Copyright 2000 Baker Hughes Incorporated. All rights reserved.

www.bakerhughes.com/bot/

Baker Oil Tools 6023 Navigation Blvd. (77011-1136) • P.O. Box 3048 (77253-3048) • Houston, Texas • Tel 713-923-5198
Headquarters 9100 Emmott Road (77040-3514) • P.O. Box 40129 (77240-0129) • Houston, Texas • Tel 713-466-1322
e-mail: bigbore.wells@bakeroiltools.com
Copyright 2000 Baker Hughes Incorporated. All rights reserved. Publication # 00/00