Section Mill Sidetrack

Section mill sidetrack: what is, and how this would be completed.

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).
The first step is to ensure that the proper equipment is on location, by determining the
size, (OD and ID), the weight and grade. Check that all the necessary 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
(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.
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.