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Tech(PE)ME(PE)

UNIT I
Well design: Prediction of formation pore pressure and stress gradients. Determination of
safety mud weight bounds for different in-situ stress conditions. Design and planning well
trajectory. Surveying tools and methods.

PORE PRESSURE
INTRODUCTION
Normal Pore Pressure
 Normal pore pressure is equal to the hydrostatic pressure of a column of formation fluid extending from
the surface to the subsurface formation

 Formation pressure equal in magnitude to the hydrostatic pressure of a column of pore fluid that
reaches from the surface to the vertical depth of the formation.

Pore Pressure
• Formation pressure is the fluid pressure with in the pore space at the time of sedimentation.
• It Can Be Expressed As an Average Vertical Pressure or Equivalent Mud Weight. E.G. psi, ppg, G/cc“

Note:
To convert from psi/ft to ppg, use:
Density (ppg) = gradient (psi/ft) / 0.052

Normal pressure gradients are in the range of water.


Examples
  Permian Basin .433 psi/ft
 Rocky Mountains .438 psi/ft
 Gulf Coast .456 psi/fi
 West Africa .442 psi/ft

Overburden Presuure
 The vertical pressure at any point in the earth is known as the overburden pressure or geostatic
pressure. The overburden pressure at any point is a function of the mass of rock and fluid above the point
of interest.

Abnormal Pressure

 Pore pressures which are found to lie above or below the ‚normal‛ pore pressure gradient line are called
abnormal pore pressures. These formation pressures may be either Subnormal (i.e. less than 0.465 psi/ft) or
Overpressured (i.e. greater than 0.465 psi/ft).

 Abnormal high pressures are caused by compaction effect, diagenetic effect, and differential density effect.
The most common effect is the compaction effect.

 The most common mechanism for generating overpressures is called Undercompaction and can be best
described by the undercompaction model.

An accurate prediction of these pressures is need to properly design the mud program to keep a well under control.
Pore pressures and fracture pressures are used in the casing design.
Methods for Estimating Pore Pressure – Most methods depend of porosity and rock density.
Before Drilling
 Available data from other wells
 Geophysical Data
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While Drilling
 Drilling rate- Decrease in ROP
  Increasing torque – At high pressure zone
 Mud log analysis - An increase in the hydrocarbons
  Cutting analysis - Can be used to find the bulk density of the formations,
 Measurement while drilling -The density log can indicate drilling into transition zone.
 Drilling fluid analysis -Changes in salinity, temperature and density
Formation Fracture Pressure
 It is the pressure needed to make a fracture in a formation.

• The orientation of the produced fracture depends on the orientation of the principal stress of the fracture
point.

PORE PRESSURE CALCULATION


Density of mud required to control this pore pressure

Pore Pressure vs. Depth


0

5,000
Depth, ft

10,000

15,000
5 10 15 20
Pore Pressure, lb/gal equivalent

Eaton equation
Quantify the magnitude of the abnormal pore pressure using overlays, or Ben Eaton’s Method

P S S P dc calculated 1.2
 − −
D
D D D n dc normal

d d mud weight for nor mal gr adient ( ppg )

actual mud weight in use( ppg)


Where,
P/D is Pore pressure gradient
S/D is Overburden stress gradient
(P/D)n is normal pressure gradient
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Abnormal Pressure Equation

D Exponent
The drilling rate equation:
D
W
E
RKN
DB
Where
R = drilling rate, ft/hr
K = drillability constant
N = rotary speed, RPM
E = rotary speed expon.
W = bit weight, lbs
DB = bit diameter, in
D = bit wt. Exponent or D – exponent
A modified version of this equation follows:

log
R
60 N
d
12 W
log
106 D
B

Formation Integrity Test


 It is the method to test strength of formation and shoe by increasing Bottom Hole Pressure (BHP) to
designed pressure.

 FIT is normally conducted to ensure that formation below a casing shoe will not be broken while
drilling the next section with higher BHP or circulating gas influx in a well control situation.

 Normally, drilling engineers in town will design how much formation integrity test pressure
required mostly in ppg.
The formula below demonstrates you how to calculate required FIT pressure.
Pressure required for FIT (psi) = (Required FIT in ppg – Current Mud Weight in ppg) x 0.052 x True
Vertical Depth of shoe in ft

Example
Required FIT (ppg) = 14.5
Current mud weight (ppg) = 9.2
Shoe depth TVD (ft) = 4000 TVD
Pressure required for FIT = (14.5-9.2) x 0.052 x 4000 = 1102 psi

Fracture Gradient or Formation Integrity:

It is usually used to indicate a test to determine the fracture gradient. In reality, the term Formation Integrity Test
has a more encompassing meaning which includes:

Limit Test:

A test carried out to a specified value, always below the fracture gradient of the formation.
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FIT Limit Test - Procedure

 Drill 10-20 ft of new formation and perform the FIT test.


  Pump equal increments of mud (usually 1/2 bbl) recording gauge pressure at each increment.
 Continue the test to the pre-calculated surface pressure value.
 A graph of gauge pressure vs. volume pumped should be plotted whilst the FIT test is being carried out.

Calculate the Fracture Gradient (FG) using the following formula:

Where
FG = Fracture Gradient (ppg)
ρ m = Mud Density (ppg)
FIT = Maximum Test Pressure (psi) after rock fracture
D = TVD (feet)

LEAK OFF TEST:

A test carried out to the point where the formation leaks off.
A test carried out to the leak off point and beyond until the formation around the wellbore fails. The fracture
gradient is equal to the earth minimum horizontal stress.

FORMATION INTEGRITY TESTS: PURPOSE

Formation strength tests can be carried out to the leak-off pressure or to a pre-determined limit as specified in the
drilling program.
The main reasons for performing a formation integrity test (FIT) are:
 To investigate the strength of the cement bond around the casing shoe and to ensure that no
communication is established with higher formations.

 To determine the fracture gradient around the casing shoe and therefore establish the upper limit of
primary well control for the open hole section below the current casing.

 To investigate well bore capability to withstand pressure below the casing shoe in order to validate or
 invalidate the well engineering plan regarding the next casing shoe setting depth.
 To collect regional information on the formation strength for optimization of well design for future wells.
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FACTORS INFLUENCING FRACTURE GRADIENT


 At any particular point below the earth‘s surface, there are three independently acting stresses which are
perpendicular to each other.
 There are three normal stresses: vertical stress (σV ) and two horizontal stresses (σH and σh).

 This notation is widely used in Rock Mechanics as it is usual to have shear stresses associated with planes
containing normal stresses.

 Normal stresses which have no associated shear stresses are described as Principal Stresses and are
mutually perpendicular to each other,
 The maximum principal stress (designated σ1)
  The intermediate principal stress (designated σ2)
 The minimum principal stress (designated σ3)

In most cases the maximum principal stress will be vertical due to the pressure of the overlying rock. This is defined
as the overburden pressure.

FRACTURE GRADIENT DETERMINATION


1. Hubbert and Wills Method
F  1 1  2P min
3D
F  1 1  P max
2D
Where,
F = fracture gradient, psi/ft,
(P/D) = pore pressure gradient, psi/ft

2. Matthews & Kelly:


K iσ P
F D D 6
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where Ki = matrix stress coefficient


σ = vertical matrix stress, psi
3. Ben Eaton:
S−P γ P
F  * 
D 1 −γ D
where S = overburden stress, psi
γ = Poisson’s ratio
Examples:

1. Calculate the value of the d - exponent if the drilling rate is 35 ft/hr, the rotary RPM is 100, and the weight
on the 12 1/4‛ bit is 60,000 lbs.
R= 35 ft/hr
N= 100 rpm
DB=12.25‛
W= 60000 lb

log
R
60 N
d
12 W
log 106 D
B

log
35
60 *100 − 2.2341
 12 *60,000  −1.2308
log
6
10 12.25
d = 1.82.

dc  d
mud weight for nor mal gr adient ( ppg )

actual mud weight in use( ppg)


Mud weight for normal gradient = 9 ppg
Actual mud weight in use = 12 ppg
dc =1.82 (9/12) = 1.37

2. If the normal pore pressure gradient in the area is 0.433 psi/ft, and the actual mud weight is 11.2 #/gal,
what is ‚dc ‛?
Normal Pore pressure gradient= 0.433 psi/ft
Normal Gradient= 0.433/0.052 = 8.33 ppg

normal gradient ( ppg) 8.33


dc  d  1.63 *
actual mud weight ( ppg) 11.2

dc =1.21
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WELL PLANNING AND DESIGNING HORIZONTAL WELL


The following factors should be considered when designing a horizontal well:
• Target definition
• Single curve Design
• Double curve design

Target Definition

A horizontal well is usually a development well with well-defined geological and reservoir objectives.

The following information is required to define the horizontal target accurately:


1. Target co-ordinates
2. Entry point into the reservoir
3. Length of horizontal drain
4. Azimuth range of target
5. Vertical depth range of target
6. Tolerance in vertical depth and displacement
7. Dip of target

 It should be observed that the entry point into the reservoir may have different co-ordinates from that of
the reservoir.
 Usually most reservoirs have marker zones which can be used as
the starting point for the final build up section before entering the reservoir.

 The marker zones are usually thin shale section which can be easily identified with gamma ray logging
tools.

 In new areas, a pilot vertical hole is usually drilled through the reservoir to ascertain the exact depth of the
marker and the reservoir, thickness of reservoir and the crooked hole tendency of the formations in the
well.

 If the reservoir has a significant dip angle, then the horizontal section must be designed to follow the dip to
maintain a constant separation above the gas or water contact.

Single Curve Design


 In this design, the hole angle is built up from zero at the KOP to 90 degrees at the entry point into the
reservoir.

 If this design is used the build up tendencies of both the formation and the rotary or steerable BHA should
be known in order to avoid missing the target due to excessive or insufficient build up rates.

 The BUR is too low the well path will fall below the target and if the BUR is too high the well path falls
above the target.
Design Equations

R=5730/ BUR
V1 =R.(SinI 2 SinI1)
H1 =R.(CosI1 CosI 2)
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Double Build Curve Design


 If the build up rate is too high the well path will be above the reservoir and the well will require redrilling.

 Similarly, if the build-up rate is too low, the well path will be below the reservoir and the drilling
objectives will not be met.

 The above problems can be solved by having a tangent section below the initial build up curve and then
build up to the required angle when reaching a reservoir marker,
 In some cases the final angle is actually built up inside the reservoir.
 If a tangent section is included, the equations for the tangent section of a double build curve are:
V 2 =L2.Cos2
H2 =L2.SinI 2
The final build up section has the following design equations:
R3 =5730/ BUR2
V3 =R3.(SinI3 SinI 2)
H3 =R3.(CosI2 CosI3)
L3= {100.(I3 - I2) }/BUR2
Torque and Drag
 In a directional well, the friction between the drillstring and the walls of the well produces drag and torque.
 Drag is produced when the drillstring is moving and torque is produced

 when the drillstring is rotating.Knowledge of torque and drag will enable the selection of an optimum well
profile and its components.

 In horizontal wells, it is usual to run the heavy-walled Drillpipe (HWDP) along the curved section of the
wellbore to counteract the forces caused by bending and drag.

The following predictions must be made when designing a horizontal well:


1. Torque and drag while drilling with surface rotation
2. Torque and drag while steering a downhole motor
3. Drag forces while tripping
4. Buckling forces on the drill string

 There are currently several propriety software packages which can do the above.

 All these packages use essentially the same equations for calculating torque, drag and buckling
forces. The following equations may be used to carry out the above calculations

Torque

1. Horizontal Section
The torque on the pipe (Th) in the horizontal section is given by 72
Th=ODWmL)/72) – ( ft lb)}
2. Final Build-Up Section
Th =ODWmR)/72) .... (ft lb)}

DRAG FORCES
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The following equations apply to tripping operations or steering with a downhole motor:

1. Horizontal Section
Dh = 0.33 Wm L
2. Build-Up Curve
Fo = Dh + WOB (14.17)
If Fo < 0.25 Wm R, then drag force (Db) in the build curve is given by:
Db = 0.4 Wm R (14.18)
If Fo > 0.25 Wm R, then drag force (Db) in the build curve is given by:
Db = 0.25 Wm R + 0.69 Fo

WELL PLANNING AND DESIGNING: EXTENDED REACH WELLS

 Extended Reach Wells (ERW) are defined as wells where the ratio of measured depth (MD) to true vertical
depth (TVD) is greater than two.
  In other words for a LRW with a ratio of two we require to drill twice the TVD to reach the reservoir.
 Hence, if the reservoir is at 10,000 ft TVD, the MD is 20,000 ft

Weight Calculations in Extended Reach Wells

1. Vertical Section
W1=V1*Wdp*BF
2. Build-up Section
Weight = length *Wdp* BF
3. Weight of pipe in tangent section
= BFxCosθT WdpxLdp + WBHAxLBHA

Buckling of Drillpipe and Bha


 Buckling of BHA’s while rotating is the main cause of fatigue in BHA connections. Buckling in vertical
and near vertical wells cannot be avoided except at very low WOB’s.

 As the hole angle increases, the BHA becomes more stable as it lies on the lower side of the well enabling
the BHA to be supported by the walls of the hole.

Critical Buckling Force


 Buckling of drillpipe occurs when the applied compressive force exceeds the pipe’s critical buckling load
 . The critical buckling force is the minimum compressive force which results in the pipe buckling.
The critical buckling force is given by

Fc= 550{(IWdp(65.5-MW)Sinθ)/(Dh*Dtj)}1/2

MULTILATERAL WELL PLANNING CONSIDERATIONS

The following is a partial list of some of the most important considerations in planning a multilateral well:

1. Drilling methods
2. Junction design
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3. Well control issues


4. Drilling issues
5. Milling problems
6. Completion requirements
7. Multi-lateral requirements
8. Abandonment

Drilling Planning Issues

There are three main drilling techniques:


• Long radius
• Medium radius
• Short radius

The drilling assemblies (BHA’s) used are typically build-up or drop angle assemblies, as described in gives the
geometries of each of the above three profiles. The planning issues to consider when drilling a lateral are:
1.Hole size
2.Hole angle
3.Kick off methods
4.Flow control and isolation
5.Formation damage and clean up of the lateral
6.Drainage patterns for optimum production

It will be assumed that factors 1,4 and 6 will be decided by the reservoir engineer for maximum productivity.
Current typical hole sizes are 8 ½" and 6" and hole angles of 80-90 degrees

Kick Off Methods

A lateral can be kicked off using one of three methods:


1. Open hole
2. Cased hole

Open Hole Kick Offs


 In open hole kick off , a cement plug is first placed in the open hole where the kick off window is desired.
 Once the cement plug is set, a kick off assembly is to build up angle away from the mother bore.
 Further build up assemblies or holds up assembly are then run to drill to final total depth.
Cased Hole Kick Offs
 In cased hole kick offs, see, a window is first cut at the position where kick off is desired. Thereafter, the
same procedure as for open hole kick offs.

WELL CONTROL CONSIDERATIONS


 Unless the junction is actually sealed both mechanically and hydraulically, it will remain as an exposed
shoe.

 The magnitude of its fracture gradient will then affect how the well is controlled during well kill
operations.
Debris Control
 The main sources of debris whilst making a junction are milling and drilling operations.

26
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PE - 502 Well Design and Completion

 Window milling is by far the major source of problems in ML operations. Milling a window in a 9 5/8"
casing typically produces 450 lb of steel swarf.

 Debris caused by the accumulation of drill cuttings can be reduced by optimising the lifting and suspension
properties of the drilling mud.

 Other sources of debris: broken pieces of downhole tools such as drillbit inserts, broken centralisers,
packer elements, excess cement, corroded products and dropped objects.

FLOW CONTROL AND ISOLATION OF LATERAL

The flow from the lateral can be isolated from flow in the main bore using
1. Sliding sleeves
2. External Casing Packer (ECP)
3. Hydraulically sealing lateral

WELL PLANNING AND DESIGNING: HPHT WELL


There are two very important points which must be considered before designing high pressure/high temperature
(HPHT) well:

 The margin between the fracture gradient and pore pressure is usually small. The difference is critical in
the design of the well.

 HPHT wells usually have high ECD’s (Effective Circulating Density) leading to lost circulation
problems followed by a loss/ gain cycle that becomes difficult to control.
The following sections provide general guidelines on how to design HP/HT wells.

 The reader should note that knowledge of the area and data from offset wells must always be used for
fine tuning the well design and equipment
Rig Selection
 For offshore operations, the choice is usually between a Jack-up and a Semisubmersible rig.
 For a land well, a heavy duty rig is required.
Mud Selection
 Accurate modelling of mud density for HPHT wells is critical due to the narrow margin between the pore
 pressure and the fracture gradient and because of the presence of a long cold riser in offshore operations.
 Mud for HPHT wells must:
 Be stable under extreme temperatures and pressure as unstable mud leads to mud gellation and barite sag
 Have optimised rheology to minimise ECD

In most countries, the use of oil-based mud (OBM) is not allowed. The choice of drilling mud is between WBM and
Pseudo-oil mud (SBM).SBM is preferred as it gives better:
 Thermal stability
 Inhibition
 Lubricity

Well Testing
The main objectives of a well test are to:
 Determine formation deliverabilities
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 Determine minimum reservoir pressure


• Obtain well fluid samples
One of the main considerations in an HPHT well test is deciding whether to use WBM, Sea water or POBM as
the test fluid.

Casing Design
 Since the majority of HPHT reservoirs contain either condensate or gas at extremely high pressures
and high temperatures,
  Extra care must be taken when selecting casing grades/weights.
 The following design considerations are usually made for HPHT wells:

 Both the 9 5/8" (intermediate/production) and 7 "(production) casings are designed for tubing leak
using either gas gradient or the condensate gradient whichever is relevant to the reservoir.

 The 13 3/8" casing is designed for possible annulus heating effects, especially for subsea wells where
the annulus cannot be monitored.
 The 9 5/8" casing is designed for buckling effects caused by high temperature.
  Both the 9 5/8" and 7 "casings properties are derated because of the high temperature.
 Both the 9 5/8" and 7 "casings are designed to withstand H2S and CO2 effects.

Cementing
The following factors must be considered:
• Cement slurries must be designed to withstand the high temperatures
• Strength retrogression of cement at high temperatures
• Retardation to allow placement of cement without premature setting
• Slurry density
• Low fluid loss
• Zero free water
• Possible H2S
• Potential gas flow
• Right angle set slurry
• Maximum top of cement to prevent buckling and annulus heating problems

Well Costing
Cost evaluation by various methodology
  As will be discussed later, there are many elements which comprise the well cost.
 These range from rig, casing, people, drilling equipment etc.

 The final sheet summarizing the well cost is usually described as the AFE: ‚Authorisation For
Expenditure‛. The AFE is the budget for the well.
 Once the AFE is prepared, it should then be approved and signed by a senior manager from the operator.

 The AFE sheet would also contain: project description, summary and phasing of expenditure, partners
shares and well cost breakdown.
 Details of the well will be attached to the AFE sheet as a form of technical justification.
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There are several reasons for producing a well cost, including:


• Budgetary control Economics
• Partners recharging
• Shareholders
The AFE is then used as a document for partners recharging, paying contractors and an overall control on the well
spending.

Factors Influencing Well Costs

Well costs for a single well depend on:


• Geographical location: land or offshore, country
• Type of well: exploration or development, HPHT or sour gas well
• Drillability
• Hole depth
• Well target(s)
• Profile (vertical/ horizontal /multilateral)
• Subsurface problems
• Rig costs: land rig, jack-up, semi-submersible or drillship and rating of rig
• Completion type
• Knowledge of the area: wildcat, exploration or development

The total well costs for a development drilling programme comprising several wells depend on:
• Rig rate
• Well numbers and well type
• Total hole depth
• Well layout and spacing
• Specifications of equipment
• Target tolerances
• Water depth for offshore wells

Technical Limit Drilling

 TLD requires that drilling estimates are made without the inclusion of invisible lost time or non-productive
 time,.
 Non productive time was discussed in detail in ‚Non Productive Time (NPT)‛Invisible Lost Time:

 This time is usually absorbed in productive time and is made up of the total of previously acceptable
wasteful events

CASE STUDY

 The following procedure for designing a multi-lateral well is based on actual wells drilled in Qatar, Ref. 7:
Scofield and Woodward, SPE/IADC 37675 1997.

 The design procedure that follows basically applies all of the above recommendations. However, it should
be noted that there are several variations of methods and tools
which can be applied with equal success.
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The Reservoir
 This contains four zones (A to D). Only the two top zones A and B are commercially productive.
 The permeability is 1-3 mD and porosity 18-22%. Each zone is approximately 80 ft in thickness.

 The upper zone is overlaid with thick Nahr Ummer Shale, making geosteering an excellent path finder. It
is intended to drill two laterals in zones A and B.

Directional Planning

 The laterals must be designed so that the window can be existed at the optimal inclination and azimuth
 angles for later drilling and completion.
 The best directional profile is one which allows the window to be placed at or near horizontal.

 This placement ensures that the maximum dogleg severity is limited to 7 deg/100 ft when drilling off a
whipstock into a new formation.
 The window joint is placed 10-15 ft above the depth where the lateral will be geosteered.

 This allows the window opening to be positioned on the high side of the hole and creating a slight uphill
exit for the window opening.

 This will prevent assemblies run specifically into the primary wellbore from inadvertently exiting the main
bore and entering the lateral.

Installation of 9 5/8" Casing in Mainbore

 The window joint is run as part of the 9 5/8" casing and must be oriented and positioned correctly within
 the main wellbore.
 Open hole log analysis will determine the exact depth at the window should be positioned.

 The casing is then made up and run until the window joint is required. The window joint is then carefully
made up and the casing is then rotated to the correct magnetic orientation using a rough line of sight
orientation to produce the required downhole orientation when the pipe is landed.

 The casing is then run in hole until an inclination angle of 20 degrees is reached. At this stage a gyro check
shot is taken of the orientation of the window joint to ensure that the window opening is at high side

Cementation

 The 9 5/8" casing is cemented conventionally with two spring bow centralisers on the each of the first five
joints and then one centraliser per joint up to the 13 3/8" casing.

 As the window joint is covered with an isolation sleeve, flexible cement wiper plugs are used to pass the 6
5/8" ID of the protection sleeve.

 Once the casing is cemented and pressure tested, a retrieving tool for the isolation sleeve is run together
with a directional MWD package.

 Once the isolation sleeve is latched, the orientation of the window opening is checked and adjustments to
the directional plan are made.

Drilling Through the Window Opening

 After the isolation sleeve is removed, a whipstock with a latch coupling made up on its bottom is run and
set in position to provide a precise orientation to the window exit.
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 The window opening is usually closed with composite material. An 8.5" milled tooth bit with bearings is
run on a mud motor.
 The bit is run on a directional assembly utilising a bent housing motor and MWD directional package.

 Once the window is drilled, the hole angle is built at 5-7 deg/100 ft to push the new wellbore away form
 the existing 9 5/8" casing.
 A new hole is drilled to approximately 150 ft length prior to pulling out the drilling assembly.

 A new drilling assembly with formation evaluation while drilling (FEWD) is then run and the lateral is
drilled to its total depth.

 The drill bit is then pulled out of hole, the lateral is logged and a short 7" liner (250 ft) is run to line the
curve of the lateral and form a window joint.

The Junction
 The 7" liner provides a junction with mechanical integrity but with out hydraulic isolation.

 The mechanical junction is required to provide long term mechanical integrity and avoid the problems of
junction deterioration associated with formation collapse.

 The 7" liner also provides a guide for drilling assemblies and coiled tubing tools that will be run during
well servicing.

 The 7" liner is run with an external casing packer (ECP) and a stage cementer. The ECP is used to prevent
cement form flowing downwards and damaging the reservoir.

 Once the ECP is inflated the stage cementer opens allowing cement to flow around the 7" liner and up to
the junction.

Washover of the Transition Joint / Drilling Whipstock


 After cementing, the well is cleaned out to the top of the 7" transition joint.
 A washover assembly is then run and the transition joint and the whipstock are washed over.
 The washover assembly contains a recovery mechanism for the whipstock.

 Once the whipstock is washed over, a no-go bushing is encountered which trips open a slip ring allowing
the whipstock, casing remnant and latch assembly to be recovered in one go.

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