Window Milling - Cement Whipstock

Recommended Practice: Window Milling – Cement Ramp Windows Page 1 of 9
Alaska Drilling and Wells

Recommended Practice: Window Milling – Cement Ramp
Windows
Authority: Drilling Manager Custodian: Drilling Engineer

Document
ADW Document Control
Scope: ADW – CTD Operations Control
Specialist
Administrator:
Alaska Drilling and Wells
Issue Date: December 1997 Issuing Dept:
(ADW)
Revision Date: March 26, 2003 Control Tier: Tier 4
Next Review Date: March 26, 2005
1.0 Purpose/Scope
This CTD “cement ramp window” sidetracking technique was developed for wellbores that cannot use
whipstocks due to adverse tubing/casing size combinations or poor liner condition (corrosion, etc). In
addition, the unlimited window orientation capability provided by cement ramps can assist certain
directional work objectives.
Cement ramp windows are typically more costly than whipstock windows, so they should only be used
when whipstocks are not a viable option (see section b for applicability chart). Cost is generally higher
due to trouble time associated with failed attempts and/or additional dressing runs. For example, poor
P&A cement quality can lead to a weak ramp that does not hold up to the milling process or subsequent
drilling BHA runs. Once the ramp is damaged the window is typically lost. In addition, lack of
experience and/or finesse during the milling process can result in incomplete windows. The detailed
field procedure (section C) addresses some of these issues to minimize repetition of the failures. A fully
successful cement ramp window job results in uninhibited passage through the casing and is completed
in 3 or less BHA runs (post P&A).
2.0 Definitions
NA
3.0 General Requirements

NA
4.0 Key Responsibilities

Drilling Engineer, Wellsite Leader
Control Tier: 4 – ADW Revision Date: 03/26/03

Document Number: UPS-US-AK-ADW-CTD-HSE-DOC-00010-4 Print Date: 01/31/03
PAPER COPIES ARE UNCONTROLLED. THIS COPY VALID ONLY AT THE TIME OF PRINTING. THE
CONTROLLED VERSION OF THIS DOCUMENT CAN BE FOUND AT http://alaska.bpweb.bp.com/ems
5.0 Procedure/Process
Cement Ramp or Whipstock Window Application Table 1/31/03
Grey boxes indicate recommended window technique (as wellbore permits, 1/31/03 update)
3.5" Production Tubing (2.74-2.80" mill) 4.5" Production Tubing (3.8" mill)
Cement Baker TIW Cement Baker TIW
Liner size Ramp Whipstock Whipstock Ramp Whipstock Whipstock
C a nno t do a t this
3-3/16" tim e
No t Ava ila ble 2.69" OD in s to c k NA NA NA
0 0 0 0 0 0
3-1/2" tim e
Ava ila ble 2/15/03 2.69" OD in s to c k NA NA NA
0 0 1 0 0 0
R
R a m p = 0' KO a t
4 1/2" TOC
Ava ila ble 2/28/03 No t Ava ila ble tim e . J o b be lo w 3 o ptio ns o n S lo pe 3 o ptio ns o n S lo pe
wa s M LAS jt.
3 2 0 1 1 1
Le g e xte ns io n o f 4
R a m p = 0' KO a t C a nno t do a t this c ha nge s lip blo c ks , 1
5" TOC
1/2" whip, 1 m o nth No t Ava ila ble
tim e
S to c ke d o n s lo pe
m o nth le a d
le a d tim e
1 0 0 0 0 0
Tho ught po s s ible ,

R a m p = 0' KO a t
R a m p = 6' but ne e d 3 m o nth No t Ava ila ble S to c ke d o n s lo pe 1 m o nth le a d
TOC
5-1/2" le a d tim e
2 0 0 2 0 1
B a ke r no t purs uing 2 o n s lo pe , no t run

7" R a m p = 8'
de s ign a t this tim e
No t Ava ila ble R a m p = 9' S to c ke d o n s lo pe
ye t.
5 0 0 4 5 0
7-5/8" R a m p = 9' No t a va ila ble No t Ava ila ble R a m p = 9.5' S to c ke d o n s lo pe No t Ava ila ble
0 0 0 0 0 0
9-5/8" R a m p = 12' No t Ava ila ble No t Ava ila ble R a m p = 12' No t Ava ila ble No t Ava ila ble
0 0 0 7 0 0
We ll To ta ls 11 2 1 14 6 2
(1/98-8/99)
Recommended Cement Ramp Window BHAs

Pilot Mill Size/Type 2.74-2.80"/ Hughes D331GEB 3.80"/ Hughes D331GEB
Pilot Motor 1.75° adjustable, 2 3/8" XP 1.25° adjustable, 2 7/8" XP
Window Mill Size/Type 2.80"/ Hughes DP0064, brass guide for 8rd 3.80"/ Hughes DP0088
Window Motor 2.5° fixed*, 2 3/8" XP (w / new output shaft) 3° f ixed, 2 7/8" XP (w / new OS)
(* Use We atherford MM w ith 2.13" bit box and bearing section)
Dress Mill Size/Type 2.72-2.78" crayola (Baker Fishing) 3.78" crayola (Baker Fishing)
Dress Motor 2.25° adjustable, 2 3/8" XP 2.25° adjustable, 2 7/8" XP
(1.75° if w indow mill w as 2.5°)
Summary of cement ramp w indow recommended procedure:
1) P&A existing w ellbore w ith 17 ppg cement leaving TOC ready for drilling of the pilot hole and ramp. Consult “RP - P&A and Plugback
Cementing” for procedure to establish a hard plug dressed to the desired depth.
2) PU pilot mill BHA to mill XN nipple, 25'+ pilot hole, and cement ramp. See charts above for ramp length and required equipment. All BHAs
have f ull MWD and orienter. The mud should be 2 ppb biozan, 2% KCL w ater.
3) PU w indow mill BHA to mill w indow and attempt to drill 5-7’ of formation. Pump clean 2 ppb bio sw eep at end to look for metal and sand
in cuttings.
4) Dress w indow w ith crayola mill to help ensure uninhibited passage of BHAs. Pump clean bio sw eep.

Detailed Field Procedure for Cement Ramp Windows
Step 1): Pre Job Research/Planning
 Confirm that the cement ramp window is the best/only option available by reviewing wellbore
size and condition and referring to the application table on page 2. Generally a whipstock is
preferred (when available), but corroded casing, casing size, and/or directional considerations
may favor a cement ramp window.
 Do not mill window through a casing collar. Overlay collar log with Geology PDC log to
locate exact collar depths. Place TOW anywhere between 5’ below a collar to 12’ above the
next collar down.
 Avoid kicking off in a conglomerate (PBU Zone 3 or top 20’ TVD in Zone 2 should be
avoided if possible).
 Check casing grade and composition. Use the “extended time mill schedule” if casing grade
is higher than L-80 (e. g S-95) or if it is 13 Cr. Higher grade casings like S-95 (RC29) are
30% harder than normal L-80 (RC22) and require extra milling time. This also applies to 13Cr
casing, but due to a smearing effect.
 Hard cement is critical to achieving and maintaining a usable window. If pre rig cementing
records and/or pilot hole drilling indicates possible soft cement, plan to underream and re-
cement ramp/pilot hole interval. As a guideline, ROPs of 20-40 fph @ 2-3 klbs WOB with the
D331GEB typically indicate hard cement. ROP over 40 fph or inconsistent ROP should be
considered suspect.
 For a typical window, plan for TOC to be ~100’ above the desired kickoff point. This
includes a 65’ safety cushion for TOC movement (during cleanout phase + contamination +
CT depth error), 25’ for pilot hole (length for all size windows), and ~10’ for ramp.
Special Cases
 Large Liners/Long Pilot holes: Under rare circumstances it is preferable to cement up long,
large diameter liners from KOP to the tubing tail and then drill an extended length pilot hole.
The smaller diameter pilot hole can improve cuttings transport and reduce CT helical
buckling. Hydraulic and CoilCADE modeling should be conducted to determine if a long
pilot hole is warranted.
Consider utilizing the long pilot hole technique when:
Coil size Tubing Tail To KOP Casing Size Inclination

2.0” >300’  7” >45°
2 3/8” >500’  9 5/8” >45°
As a guideline, long pilot holes have fallen out of favor in CTD. The longer pilot hole may
result in 2 extra BHA runs to mill the XN nipple and pilot hole/ramp since a PDC would
likely be used to drill the longer cement hole. In addition, GR tie in runs must be logged at
lowside orientation to avoid the risk of sidetracking in the cement.

 Small Liners: Consult the application table (page 2). When window mill size vs. liner size is
very close, the diamond speed mill/cement ramp technique cannot be utilized (unsuccessful at
this time):
2.8” mill in 3 3/16”or 3 ½” liners 3.8” mill in 4 ½” or 5” liners
- Just after the start of milling, nearly 180 degrees of the mill face is trying to cut
steel. Diamond contact area is too large for the force available resulting in slow or
non-existent ROP.
In addition, for slightly larger liners a diamond speed mill can cut the window, but a cement
ramp and pilot hole is not utilized (Ramp = 0’):
2.8” mill in 4 1/2”or 5” liner 3.8” mill in 5 ½” liner
- Thin cement chunks could break off the liner wall. The cement plug should be
underreamed to KOP and the window milling procedure starts at a flat top of
cement. (skip step 2, start at step 3 below).
Step 2): Mill XN Nipple, Drill Pilot Hole and Ramp
1. Plan to mill the XN and cement pilot hole/ramp with 2 ppb biozan 2% KCL water.
2. RIH w/ the following assembly to mill open the XN nipple and drill the cement pilot
hole/ramp. See table on page 2 for mill & MM size.
- Hughes Christensen D331GEB parabolic diamond speed mill.

- Bent housing MM w/extended power section (no kick pad)
- Normal drilling BHA with MWD (TF and gamma ray), orienter, and motor head
assembly (circ sub, HD, checks), CTC.
3. Tag XN nipple (if exists) and reset CT depth to EL corrected if available. Mill XN with 1-2
Klbs WOB (typically <15 minutes) and backream through. Drift with pumps off.
4. Tag & verify cement top (TOC). PU and log GR to tie into PDC log.
5. Orient the Tool Face (TF)180º opposite of proposed window direction while in the casing.
Consult the table on page 2 for the length of pilot hole to drill. Drill the pilot hole, holding
this TF to the “top of the ramp”.
6. Orient TF to the proposed window direction (should be 180° different than upper pilot hole).
Drill the cement ramp to the length specified in the table and intersect the casing wall.
Cement Quality: If suitably hard cement is not found at the expected depth, underream and re-
cement or evaluate moving the KOP further downhole. As a guideline, ROPs of 20-40 fph @ 2-3
klbs WOB with the D331GEB typically indicate hard cement. ROP over 40 fph or inconsistent
ROP should be considered suspect.
Hitting the casing: Sometimes hitting the casing wall results in erratic movement
of the toolface. If this occurs within 0 to 2’ ahead of recommended ramp length,
stop drilling and POOH for window milling BHA. Regardless, do not exceed the
recommended ramp footages in the table.

- Drilling down the casing wall by 3-4’ too much could cause the window mill BHA to bind
up in the ramp/window area. This is because the ramp builds angle, drilling down the
casing wall drops angle, and finally the MM trys to build angle again. These opposing
doglegs may prevent BHA passage through the window.
- On the other hand, a ramp that is too short may result in the window mill skidding down
the casing. The long time milling intervals at the start of the procedure are wasted in getting
the mill to the casing wall and no lip is formed. Subsequent time intervals are too fast to cut
a lip and the mill skids down the casing wall. The time milling table trys to compensate for
this situation by increasing time intervals at the 1’ mark (see time mill schedule).
7. Pump a clean 2 ppb bio sweep and PUH above TOC maintaining orientation. Run into pilot
hole ~10’ several times to dress the entrance for the window mill run. Tie in with Gamma
Ray to determine exact TD. Flag pipe and POOH.
Step 3): Milling the Window
8. RIH with the following BHA to mill the window. See table (page 2) for mill/MM size.
- Hughes Christensen 2.80” (DP0064) or 3.80" (DP0088) 1-step diamond speed mill.
- Fixed bend MM w/extended power section (no kick pad). Kick pads have hung up on
the ramp. Note: Ensure MM vendor provides a motor with a new output shaft due
to stresses incurred during milling. On slimhole jobs use a 2 3/8” Weatherford MM
with a 2.13” bit box and bearing section. (Surface testing by Hearn indicates that this
special clearance section of the MM is required to avoid casing interference on
slimhole windows.)
- Normal drilling BHA with MWD (TF and gamma ray), orienter, and motor head
assembly (circ sub, HD, checks), CTC.
- Two drill collars should be added above the orienter to stabilize the toolface if it was
erratic throughout the pilot hole run.
Note: If 3 ½” tubing connection is 8rd EUE, the 2.8” mills have a tendency to hang up in
the collars. Plan to reduce MM bend to 2.5° and/or braze a brass guide ring onto mill.
Baker fishing has guide ring specs.
9. Ensure 3+ magnets are located in shaker return trough. RIH without pumping (no shallow
hole test) to avoid damaging the window mill shoulder diamonds and production tubing. If
the BHA hangs up in collars, etc. it may be necessary to roll the pumps to get by. Tie into
flag. RIH to ~5’ above the cement ramp.
10. The mill can quickly damage the ramp when running in hole with the pumps on with the
wrong toolface. Two scenarios (a & b) assuming a hydraulic orienter are presented that try to
minimize this situation. (CoilTrak or TORC do not have this problem).
Bring the pumps on with the mill above the cement ramp. Keep the coil moving slowly in the
uphole direction & check the tool face orientation.
a) If by chance the toolface is within 30 of the ramp orientation, cut the pump to
minimum rate to maintain orientation & carefully tag bottom. PU ~10’ off bottom
(pumps still at minimum rate) and RIH prepared to flag pipe. Bring pump up to full rate
2’ off bottom, tag, and flag pipe.

b) If orientation is needed, shoot for 60L-0 of ramp orientation while above the ramp,
taking care to keep moving in only the uphole direction while the pump is running. Shut
down the pump & RIH to carefully tag bottom. PU ~10’ with pumps off. RIH prepared
to flag pipe. Bring pump up to full rate 2’ off bottom (should get a click), tag and flag
pipe.
Note: If the tag depth is within 3’ to expected, continue. Otherwise, it may be necessary to
tie in with gamma to determine an accurate measured depth (MD).
11. Pull out 1’ from the flag to reduce compression in the coil without moving the mill. Note
torque reaction, & correct tool face if necessary. With a hydraulic orienter, cycle the pump
w/o moving the coil to rotate the orienting tool & bring the tool face to 30° of ramp
orientation. PU & repeat Step 10 if on-btm orientation is not successful. Execute the
following time drilling schedule once the TF is oriented correctly. Check ditch magnets
frequently for steel cuttings.
Standard Time Mill Schedule Extended Time Mill Schedule
md time  time md time  time

0 0.0 0:00 30 0 0.0 0:00 45
1 0.1 0:30 24 1 0.1 0:45 36
2 0.2 0:54 20 2 0.2 1:21 30
3 0.3 1:14 18 3 0.3 1:51 27
4 0.4 1:32 17 4 0.4 2:18 25
5 0.5 1:49 16 5 0.5 2:43 24
6 0.6 2:05 15 6 0.6 3:07 23
7 0.7 2:20 14 7 0.7 3:30 22
8 0.8 2:34 13 8 0.8 3:52 21
9 0.9 2:47 12 9 0.9 4:13 20
10 1.0 2:59 22 10 1.0 4:33 33
11 1.1 3:21 18 11 1.1 5:06 27
12 1.2 3:39 15 12 1.2 5:33 23
13 1.3 3:54 13 13 1.3 5:56 20
14 1.4 4:07 12 14 1.4 6:16 18
15 1.5 4:19 11 15 1.5 6:34 17
16 1.6 4:30 10 16 1.6 6:51 16
17 1.7 4:40 10 17 1.7 7:07 15
18 1.8 4:50 9 18 1.8 7:22 14
19 1.9 4:59 9 19 1.9 7:36 13
20 2.0 5:08 8 20 2.0 7:49 12
21 2.1 5:16 8 21 2.1 8:01 12
22 2.2 5:24 7 22 2.2 8:13 11
23 2.3 5:31 7 23 2.3 8:24 11
24 2.4 5:38 6 24 2.4 8:35 10
25 2.5 5:44 6 25 2.5 8:45 10
26 2.6 5:50 6 26 2.6 8:55 10

27 2.7 5:56 6 27 2.7 9:05 9

28 2.8 6:02 6 28 2.8 9:14 9
29 2.9 6:08 6 29 2.9 9:23 9
30 3.0 6:14 6 30 3.0 9:32 8
31 3.1 6:20 6 31 3.1 9:40 8
32 3.2 6:26 6 32 3.2 9:48 8
33 3.3 6:32 6 33 3.3 9:56 7
34 3.4 6:38 6 34 3.4 10:03 7
35 3.5 6:44 6 35 3.5 10:10 7
36 3.6 6:50 6 36 3.6 10:17 6
37 3.7 6:56 6 37 3.7 10:23 6
38 3.8 7:02 6 38 3.8 10:29 6
39 3.9 7:08 6 39 3.9 10:35 6
40 4.0 7:14 6 40 4.0 10:41 6
Notes:
 When milling in harder casing grades (e. g. S-95) or 13Cr, use the extended time mill
schedule.
 Mark the coil in 0.1’ increments after locking the brake. Do this in sight of the
operator. This will provide him a check on depth control, should there be problems
with the depth encoder.
 The time drill interval increases at the flag as a precaution. If the pilot mill BHA did
not drill the ramp at the predicted build rate, the 1-step mill may not have been in
contact with the casing at the start of the time drill sequence. This hesitation at 1’ gives
the mill a 2nd chance to start a ledge.
12. The mill should begin taking weight before completing the time drill schedule. Reduce the
penetration rate from that specified in the schedule as WOB increases to 4000# for 2 7/8”MM
(or 3000# for 2 3/8” MM), & continue the reduction as necessary to keep the WOB below
7,000# (4000# for 2 3/8”MM).
13. If the mill has begun to take weight, continue to Step 13. If not, or if there is any question the
mill has engaged the casing and established a lip, PU >10' above the flag, RIH to the flag.
Repeat the procedure laid out in Step 10, without the 1’ pick-up. This will move the top of
window (TOW) 1’ downhole.
14. Continue milling, increasing the WOB gradually to 6000-7,000# for a 2 7/8” MM (or 3-4000#
for 2 3/8” MM). Expect a penetration rate of 0.5'-2'/hr. The centerline of the mill should cross
the casing wall at some point 2’-4’ below the KOP. WOB may be increased up to 10,000# (or
6000# for 2 3/8” MM) if the penetration rate drops below 0.5’/hr. The forces exerted on the
mill by the casing are reversed as center of the mill crosses the casing wall, so milling may
become rough at this time. Reduce WOB until a new stable cutting pattern can be
established, then re-establish and maintain the original WOB. The concave face should
prevent any abrupt changes in hole direction.
Note: Because the forces on the mill are reversed as it cuts from inside to outside the casing,
there may be a tendency for tool face to rotate CW. If so, it may be necessary to index the
orientor all the way around to correct back CCW.

15. The penetration rate should increase substantially once the mill drills off the casing wall.
Record the depth where drill-off is observed as the bottom of the window. Continue drilling
no more than 7' of formation. Pump a clean 2 ppb bio sweep around to check for formation
sand. Tie in w/ gamma ray, flag pipe, POOH. Examine the center diamonds for wear,
indicating crossing of the casing wall
Note: This BHA has the capability to drill formation at a very high curvature. Limit the
length drilled below the window to minimize problems passing drilling BHA’s & liners.
Step 4): Dressing the Window
16. RIH with a metal muncher crayola dress mill (w/4-6” of gauge), bent housing XP motor, and
full drilling BHA (see table for mill/MM sizes). This mill has a pointed tip to help guide the
mill into the window and hold it there. The gauge cutters then do the dressing. In addition,
metal muncher cutters on the pointed tip may drill additional hole (more insurance for the
PDC bit drilling BHA) depending on formation type. Metal munchers dull quickly in
consolidated sandstone.
Tie into flag and gamma ray. Orient to the window direction above TOC and attempt to run
through the window dry. If the mill stacks out on the window, PU 10’ and RIH to 2’ above
tag and roll pumps while trying to get by. As a last resort, several windows have been milled
through at full pump rate with the crayola, again being sure to have proper orientation. Bring
pumps to full rate at no more that 2’ above window, and ream through the window and to
bottom as fast as possible.
Note: Downreaming the window with the metal muncher crayola carries the risk of
drilling cement down past the window inside the casing (losing the window). If the metal
muncher crayola cannot make >1 fpm ROP through the window without repeatedly
stalling, consider pulling OOH for the less aggressive, bald cap, cut-rite version of the
mill to dress the window. This mill will not make additional hole in cement or formation.
Once through, back-ream at 10'/hr from 2' below to 2' above the window to dress the window.
Repeat the drift w/o pumping, if possible. Repeat the reaming & drift procedure at least twice
more at +-30° orientations. (Index the orientor below the window.) Do not attempt to mill
down through the window at any orientation significantly different (from 30  CCW to 60
CW) from the direction it was originally milled to avoid damaging the cement ramp. The
crayola must be able to easily drift the window dry at ramp orientation before backreaming
can be called complete.
17. If possible, drill any additional depth required to insure the PDC bit is clear of the casing on
the subsequent run. If the first bit run will require a significant change in tool face, orient to
make some of that change while drilling additional depth with the dress mill. Metal muncher
buttons wear rapidly in sandstone so only a few feet of drilling may be possible. Circulate
clean 2 ppb bio sweep around. Tie in w/ gamma ray, flag pipe, & POOH.
6.0 Key Documents/Tools/References
RP CTD Sidetrack Prep – Plug and Abandon Existing Perforations (ensure updated for 17 ppg
ramp cement)

Revision Log
Revision Date Approving Custodian/ Revision Details
Authority Author
December 1997 Original Issue
March 31, 1999 Drilling Manager John McMullen

March 26, 2003 Paul Hyatt Mark O. Johnson Complete rewrite for all ramp sizes
<< Revision date >> << Approving << Author’s << Brief Description of Revision >>
Authority’s Name >> Name >>
Mark O. Johnson for Paul Hyatt (or, see attached e-mail ) 3-26-03
Approving Authority signature Date


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Recommended Practice: Window Milling – Cement Ramp Windows Page 1 of 9

Alaska Drilling and Wells

Authority: Drilling Manager Custodian: Drilling Engineer

3.0 General Requirements

4.0 Key Responsibilities

Control Tier: 4 – ADW Revision Date: 03/26/03

Tho ught po s s ible ,

B a ke r no t purs uing 2 o n s lo pe , no t run

Recommended Cement Ramp Window BHAs

Control Tier: 4 – ADW Revision Date: 03/26/03

Detailed Field Procedure for Cement Ramp Windows

Step 1): Pre Job Research/Planning

Consider utilizing the long pilot hole technique when:

Coil size Tubing Tail To KOP Casing Size Inclination

Control Tier: 4 – ADW Revision Date: 03/26/03

Step 2): Mill XN Nipple, Drill Pilot Hole and Ramp

- Hughes Christensen D331GEB parabolic diamond speed mill.

Control Tier: 4 – ADW Revision Date: 03/26/03

Step 3): Milling the Window

Control Tier: 4 – ADW Revision Date: 03/26/03

Standard Time Mill Schedule Extended Time Mill Schedule

md time  time md time  time

Control Tier: 4 – ADW Revision Date: 03/26/03

27 2.7 5:56 6 27 2.7 9:05 9

Control Tier: 4 – ADW Revision Date: 03/26/03

Step 4): Dressing the Window

6.0 Key Documents/Tools/References

Control Tier: 4 – ADW Revision Date: 03/26/03

March 31, 1999 Drilling Manager John McMullen

Control Tier: 4 – ADW Revision Date: 03/26/03

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