Section Mill Re-Entry

Section mill re-entry: planning and completing

Section milling operations are primarily used to mill complete sections of casing, so that new pay zones
can be accessed or opened up by sidetracking, to conduct gravel packing operations used to repair or
improve cement jobs, and/or for perforating new zones. The benefit of doing a section mill sidetrack is that
it eliminates the need for a whipstock, running a gyroscope and milling a window. Another benefit may be
that with some gyroscopic instruments, the survey quality tends to deteriorate as the inclination increases
past 70 degrees, so by eliminating the need for a gyroscope, sidetracking from a milled section of a cased
hole in a horizontal well is possible with the use of pulse survey tools (EM survey tools can be used as
well, but require a longer casing free area to function).

Pre-Job Planning
The planning phase is when the needs of the customer are addressed, and information must be obtained
from the customer to organize tools, personnel and scheduling. Data such as well location, hole size and
depth, casing sizes and depths, bit type, mud system, hydraulics, any available offset well data, formation
types, and finally any special considerations or anticipated anomalies. A ‘Well Prognosis’ or ‘Stick
Diagram’ will have enough if not all the information required to at least begin the planning processes.
Planning a section mill re-entry will require a target, the casing O.D. and I.D, Casing Calibration Logs,
Collar Location Logs, and Cement Bond Logs before the tools required can be identified. Any existing
casing tallies that can be found will help to determine the best section to be milled and may have to be
relied on in lieu of the absence of any log information to ‘rough’ plan the job, until the required logs are
obtained.
Hydraulic, torque and drag models should be sampled to determine if additional tools such as stabilization,
jars, reamers, hole openers, etc should be used. Determine the best survey system to use with the given
parameters. Determine the best mud motor to use with consideration of the bit speed, horse power, and if
any special requirements such as special stators, offset pads, etc. Choose the BHA with concerns of
doglegs, inclinations, and the ability to fish out of the hole if needed (Tool OD vs. Hole ID). Magnets for
the cuttings should also be included. If required make any possible recommendations to the customer

Job Completion
The first step to completing the section mill re-entry is to ensure that all the necessary motors, tools, jars,
whipstocks and required cross overs required are on location. Measure and record; the lengths, the OD’s
and the ID’s of all the equipment. By ensuring the right equipment is on location immediately, there may
be a chance of correcting/avoiding delays in the operation due to a delivery or planning error while
preparing the well for the sidetrack. Verify the drill pipe count on the rig and if possible the pipe tally to
verify depths later on.
The next step will be to determine the depth to sidetrack from the original wellbore. A Casing Calibration
Log, a Collar Location Log, and a Cement Bond Log should be run prior to planning the exact location of
the sidetrack. If possible the logs could also be compared against any existing casing tallies, as a double
check for depths. The Cement Bond log when run past the proposed sidetrack area will help to determine
the best point to kick off from the well bore. A Collar Location Log will locate the casing collars, which
will also help to determine the most suitable area to mill the casing for a sidetrack. A Casing Calibration
log will help to determine the doglegs in the casing string, which may help in selecting the best location to
sidetrack from as well.
A section mill assembly is then run in the hole to the depth 10-20 meters below the sidetrack assembly is
to be set. The cutters of the section mill (which are preset to the desired diameter at surface) are
hydraulically expanded and the wellbore and casing are cut thus eliminating severe doglegs and producing
a usable section to set the cement plug, open a section long enough to allow a sidetrack assembly, and
enough section so that the survey instrument will be clear of any cased hole for tool orientation. A
watermelon mill or string mill above the section mill should be run to grind or break up any cutting piles
 Section Mill Re-Entry (continued)

(bird nesting) so the cutting can be circulated to surface with high viscous sweeps, and to ensure that any
lips or burrs which may interfere with pulling the section mill back are eliminated.
The magnets should be checked regularly, for two reasons. The first reason is to examine the size of the
cuttings to determine the condition of the cutters as the milling operation is underway, and the second to
determine if the hole is getting cleaned properly. Higher viscosity sweeps should be run at a rate of 1-2 per
circulation (depending on the depth and circulating times) while milling. The parameters of the service
company supplying the casing cutter should be followed to the letter to avoid any issues that might result in
short pay to the company.
A Casing Scraper run may be required, especially if the well had been in production, or even out of
production for awhile and would have higher degrees of scale and wax build up. This would ensure there
are no blockages that would interfere with the milling assembly, sidetrack assembly, and circulation issues
such as increased pressures due to reduced hole ID, or bird nesting from metal cuttings from the milling
process, etc.
The Casing Scrapper should be run to a point 10 -20 m below the point were the sidetrack. The area should
be worked several times, circulating throughout. Higher viscosity sweeps should be run at a rate of 1-2 per
circulation (depending on the depth and circulating times) Check the shaker screen for evidence of scale,
wax and metal fillings (ditch magnets should be placed in the possum belly of the shaker and if extras are
available in the trough below the shaker). Before tripping out do a quick pipe count and check against the
pipe tally, then strap the pipe on the way out of the hole.
Set a cement plug 5- 10 m above the bottom of the milled casing depth, 5-10 meters above the sidetrack
depth. Ensure the plug has set (generally 18-24 hours) before attempting to polish the plug, by running in
with a rotary assembly and tooth bit to tag the plug. With the pumps at a reduced rate, to avoid the cement
migrating into the drillstring, put 3-4,000 daN on the plug, if the string weight remains unchanged, bring
the pumps up to normal drilling rate, and add more weight on the plug to a maximum of 8,000 daN, if the
string weight remains then the plug has set. The top 1-3meters of the plug may wash away due to
contamination of the cement, if more than this washes away, stop and let the plug set for a 2-4 more hours
before attempting the polish again. . If the plug won’t harden or is much lower than were it was spotted, run
another plug and retest after allowing it to set.
Polishing the plug is a procedure that takes time and patience. Maintain a medium rotary speed of 40-60
rpm, and maintain a consistent 3-4,000 daN on the bit (do not use the auto-digger), with the pumps at
normal drilling rates. Time drill the plug at a rate of 1-1 ½ m/hr, metering in to the desired depth. Samples
should be caught every 0.5 meter as the drilling is conducted to ensure the assembly is still on the plug, and
to get a feel of what is coming over the shaker which will be relevant to the sidetracking operation later on.
Once the desired depth has been achieved trip out of the hole strapping the pipe on the way out.
Make up the sidetrack assembly, using a medium speed motor, and a fresh sharp long toothed bit with
gauge protection. Set the motor to 1.83 degrees, or use a fixed bend motor with a 1.75 degree bend. Design
the BHA so as to avoid running any Hevi-weight drill pipe above 60 degrees inclination. Strap in, while
tripping in the hole to ensure accuracy of bit placement on the spot where sidetrack is to begin. Record the
stringweight.
Begin the sidetrack by conducting a survey that will be used as a benchmark survey later on. Spot the bit
and orient the toolface in the direction of the kick off, that was previously calculated, and by metering in,
slowly time drill meter by meter. The first meter (pending formation) should generally take 2 hrs, the
second meter 1½ - 2 hrs, the third, fourth and fifth meters roughly ¾ -1 hour each. After the first 4-5 meters
(pending formation, if softer; 5-6m, if harder; 3-4m) have been drilled, the rate can be increased to ½- ¾
hour per meter.
Catching samples regularly is very important to determine the progress of the sidetrack. The cuttings to
cement ratio will increase as the sidetrack kicks off from the existing well bore until only cuttings should
be caught in the samples thus indicating the sidetrack has been successful. Watch the weight indicator
closely and the pump pressure for signs of sidetracking, the indications may be increased differential.
While time drilling the drum brake should be squeaked by hand, do not use the Auto-digger, do not rush the
project or try to make up any lost time, and pay attention for signs of differential sticking.
After the first single of pipe has been drilled down, the process may be sped up slightly to a rate of ½ hr
per meter. If a connection is required do not rotate the drillstring or work the connection.
 Section Mill Re-Entry (continued)

Depending on the length of the survey probe to bit, a survey could be shot and the results compared with
the benchmark survey taken earlier. If the probe to bit distance is too long to determine any results, drill
ahead 5 meters and do another checkshot survey, again comparing the inclination and azimuth of the
surveys.
Once it has been determined that the sidetrack has been completed, the assembly may be tripped out to
reset the motor or change bits if required. To run back in the hole, instruct the driller to run in slowly when
going through the sidetrack, with the motor oriented in the direction of the sidetrack, avoid pumping at the
time as well.
Depending on drilling conditions and/or formations, a trough 5 or so meters ahead of the spot to sidetrack
may be considered as an option. This is done by orienting the tool face to the direction of the kick off. Drill
with a bit speed of about 40-60 rpm, and maintain 3-4,000 daN on the bit, pumping at a normal drilling rate
(or adjust the bit speed on the motor within the allowable flow range). The time taken to achieve this will
depend on the formation being drilled; generally about an hour should suffice (pending formation type).
Another option that may be considered, again depending on the area, drilling conditions and formation
types is to test the ledge. Test the ledge by first marking the single above the table (or Kelly bar), kill the
pumps, and set weight to see if it will hold. If the string falls off with only 2-3,000 daN then repeat time
drilling to build another ledge and test again. If the ledge holds 4-5,000 daN, pull back to the mark on the
single and bring the pumps up, and resume drilling the sidetrack.
In conclusion the key to a successful sidetrack is patience and diligence. Take the time required; double
check the plan, the numbers, the tallies, the depths, the pressures, and the samples.