SPEAADC 37665 Sidetracking in a Single Trip Greg Miller, Charles Dewey, and James Saylor, Smith Int. Inc. ADC Members ep 197, SPEINEC Dtng Cnc “Ts ter nasser by an SPEIADC Pagan Cate loin ow [abroad an taac xbmrinc ye ee] Cones ete pw bs ‘Seon ave bn rowed by Pe Sos 3 Pes Eng a sub xresanby be aon) The mam teeta does recy Wet ry pecton ‘Site aPt Wot neem ormanbers Paper steno oin SPEIAGS wings Snes puseaion me by Eso Carman fe SPE ard AOC Ehcne ‘ovact mat conan cope maronmray o wher a0 yam 6 pon Abstract Historically, sidetracking through existing casing requires ‘multiple trips to effectively mill a useable window for the next directional drilling assembly. The number of trips needed de- pends upon the sidetracking tools capability and performance and a comfort level of the drilling engineer in charge. This paper presents a tue one-tip system for sidetracking ‘operations. The paper will discuss desiga criteria, engineering analysis and validation ofthe design by detailed test data from field tests including photographs of actual window profiles filmed by @ downhole video camera. The objective of the one-tip system is to accomplish the following seven steps in a single trip: (I) run assembly; (2) orient whipface (with MWD); (3) set (hydraulically) whip- stock assembly; (4) separate the mill from the whip-stock; (5) mill window; (6) drill rat hole; (7) pull out of hole. The result is a fullsize window with a minimum of milling time and a full-size at hole fora dsectional diling assembly. The paper will discuss the technical innovation incorporated inthe four major components of the system, namely: (1) flow switch, operationally manipulated by pump pressure, provid- ing on/off mode for flow required for MWD orientation, cir culation and anchor seting; 2) running tool, to hydraulically set the integral packer and anchor; (3) milling tool, a 3-in-1 mill, each with different objectives and dressed with pre- formed and crushed carbide and finally; (4) the whip-stock ‘which includes ¢ multiramp design to guide the mill effec- tively and expediently (Fig. 1). Also discussed will be conti- ‘butions made by computer programs for bortom hole assembly and hydraulic analysis ofthe one-trip sidetracking system. 785 Sooty Patoiaun Engines Introduction It is apparent that one of the major problems in sidetracking, casing is achieving the initial cut into the casing, Producing. this cut out is normally done using the starter mill. Since the purpose is to achieve the sidetrack in one trip, the use of a starter mill was not an option. Typically, the starter mill has an extension below the milling portion tha is used to push the cutting area off the whipface and into the casing wall. The next mill into the hole then picks up atthe cut out, and contin- ues milling the window. The mill used in a one trip system, rust be able to efficiently cut out of the casing as well as mill the rest of the window and drill the desired rat hole. Other systems may use a wedge, ramp, or block to initiate cut-out while protecting the whipface from the mill. The ramp device may be configured in any number of ways, but usually has to bbe milled away at some point during the operation. With the system being presented here, no such ramps are needed. The special design of the mill and the whip-stock ensure that the fwo components work together to achieve the, sidetrack. Design Criteria ‘The major design criteria was to sidetrack a wellbore in one trip in 9-5/8 inch casing. It was broken into multiple design tasks as follows: © Make-up the one trip assembly on the rig floor with ‘minimum time and run in the hole to desired depth. Orient and hydraulically set the anchor. Shear-offat a predetermined value. Create a full size window (size to be the same as the drift of the casing, 8.50 inches). ‘© Drill full gage rat hole (same diameter as casing drift, 8,50 inches). The rat hole should also be allowed to be as short as possible. © Pull the milling assembly out of the hole without resis- tance. © Make-up and run the directional drilling assembly for 8.50 inch hole and drill further, ‘© Pull out ofthe hole withthe directional drilling assembly.2 GREG MILLER, CHARLES DEWEY, JAMES SAYLOR * Retrieve the whip-stock assembly by running the retrieval tool, catching onto the assembly, pulling to release the anchor, and pulling out of the hole. Engineering Analysis Analysis of Casing to Mill to Whip-Stock Interaction. The following discussion explains why the one-trip mill cuts into the casing more efficiently than other mills and does not mill ‘the whip-stock away (itis a whip-stock friendly mill), The main obstacle to overcome in producing the initial cut into the casing is generating the required side force to get the rill through the casing wall. First, the mill is pushed back into the whipface because of its contact with the casing. As the casing is cut by the mill, the total area of steel being cut increases, until it breaks through the outside wall of the ca ing. ‘This causes the mill tobe pushed even harder towards the whipface. Secondly, the shaft of the mill wants to remain straight. As the shaft deflects, the force of the mill on the whip-stock increases even further. How to overcome these increasing forces asthe mill progressed was the basic concern ‘when designing the system. In order to make the mill cut the casing more thar the whip- stock itself, a mill was produced that would more aggressively attack the casing rather than the whip-stock. This meant that the mill must have a greater contact area with the whip-stock than with the casing. What this produces is a much higher contact stress on the casing than the whipface, ensuring that the casing is cut away faster than the whip-stock. To achieve this goal, a change in the mill design was requited. Testing results demonstrated that a conventional square bottom mill ‘would initially mill the whip-stock instead of the casing. Of course, this is assuming no other device is incorporated to push the mill away from the whip-stock. This is logical be- cause intially the gage area of the mill is in contact with the casing and only the very lower corner of the mill isin contact with the face of the whip-stock. What this creates is a much higher contact stress on the whipface than on the casing, dic- tating that the whip-stock is severely cut into while the casing is not cut through as desired. Initial Milling. The mill was designed with a profile that contained surfaces that more closely matched those of the surfaces on the whipface. This meant that several different surfaces had to be produced on the mill to correspond to the whip-stock surfaces. The lower most taper on the mill is ag- aressive to match the angle atthe top of the whip-stock (Fig. 2). This initial angle is used to quickly force the mill into the wall ofthe casing and achieve cut out. There is also another very important feature that is produced by this unique mill design. The aggressive angle at the very top of the whip-stock means that it's thickness increases rapidly. This allows for sufficient room to install an attachment/oreak bolt through the top of the whip-stock and the bottom of the mill while mai taining a full gage lead mill. This is very important if « short 786 SPE full gage rat hole is desired (Figs. 3 and 4). The length of the full gage section of the mill is reduced so as to produce @ high contact stress info the casing. This surface also closely matches the straight section of the whipface. At this point milling is straight, so side forces on the mill ae less severe (Figs. 5 and 6). Between the fll gage area and the aggressive lower taper, there is an intermediate taper that closely matches the majority of the whipface. The whip-stock material is heat treated steel that is much harder and stronger than the casing. The casing therefore, be- ccomes relatively more sacrificial. No hardfacing is used on the ‘whipface, so undesirable damage ‘othe mill is avoided. Mid-ramp Accelerator. The mid-ramp accelerator prevents the mill from coring and reduces milling time (Fig. 7). Mills tend to stall when the center of the mill is on the casing wall This occurs because of the reduction of cuting element speed (the carbide) as the center of the mill approaches the casing wall. At a whipface of 3 degrees or les, it takes a substantial amount of progress to push the center of the mill from just inside the wall ofthe casing tothe outside edge ofthe casing If the center of the mills forced across the wall of the casing with a more aggressive angle, then less milling is done by the center. This reduces milling time while also preventing the mill from coring, If the mill cores severely enough, then milling will stop and the assembly will have o be pulled. A subsequent mill run is then needed to finish the window. ‘Mill Dressing. The mill dressing consists of an application of both crushed carbide as well as pre-formed carbide for faster, more consistent milling. ‘The pre-formed carbide incorporates multiple chip breakers to ensure that cuttings can be easily removed from the well bore. If longer stringers of metal are produced by the mill, it becomes difficult to push them up hole and ultimately slows the milling and drilling process. ‘The crushed carbide is a stable structure not easily chipped or wom away, thus helping the mill remain full gage. Gireulation. Drilling Aid is circulated during the milling and drilling process to keep the cutting structure cool and to clean the hole. An optimum amount of circulation is desired aring the milling ofthe casing and the drilling ofthe rat hole. After the anchor has been set, circulation ports in the mill are ‘opened to provide circulation to the most needed areas. One port is opened when the attachmentbreak bolts parted More ports are opened upon starting the milling process using breakaway caps that break when contacting the whip-stock surface during rotation. The number of ports may vary. Validation ‘Two tests were performed on the system to validate the design criteria, engineering analysis, and overall tool performance. Uncemented Casing Test. This test was performed to prove out the window cutting ability of the profiled mill and multi- ramp whipface. The casing was retrieved to examine the win-SPE dow profile ‘A 12-1/4 inch hole was drilled to a depth of 450 feet, and 9- 5/8 inch-47 Ibs/ft, P110 grade casing was run into the hole. ‘This casing was not cemented so it was secured at the surface. The system was made up and run into the hole to a depth of 380 feet. After setting the anchor, the mill was pulled off the whip-stock, breaking the attachmentbreak bolt. Several problems with the test set-up occurred during the milling of the window that dictated that the mill be pulled from the kole. ‘That aside, the window was milled in 11 hours. The mill was pulled from the hole and the casing was retrieved. The mill ‘was successful at cutting out and milling the window. The window was over 8.50 inches wide and about 12 feet in length. Cemented Casing Test. This test was performed to recon- firm the system's performance by cutting a window, running a directional drilling assembly and then retrieving the whip- stock, This test also used 9-5/8 inch-47 Ib/ft, P110 grade cas- ing, this time cemented ‘A 12-1/4 inch hole was drilled to 794 feet. The casing was, run to a depth of 778 feet and cemented in place. The side- tracking system was made-up and run into the hole to a depth of 729 feet. After setting the anchor, the mill was pulled off the whip-stock, Milling of the window then began and conti ‘ued until the lead mill reached the bottom of the whipface, 5.5 hours later. The milling rate was about 2 f/hr. Eleven feet of rat hole was then drilled in approximately 2 hours. The hole was blown dry so that a downhole video camera could be run in on wireline. The mill was pulled from the hole and the video camera run down, The camera verified that the window hhad been cut. A drilling assembly was made-up and run into the hole. This BHA consisted of an 8.50” bit on a full gage integral blade near bit stabilizer, made up to 6 inch drill col- lars, The assembly passed through the window and reached the bottom of the rat hole. Running Procedure ‘The one-trip mill is picked up first and set in the slips. The running tool is picked up and made up to the top of the mil ‘This assembly is picked up and raised over the hole. The whip-stock anchor assembly is then picked up and lowered into the hole, leaving access to the top of the whip-stock. The running tool and one-trip mill ae lowered until the lead mill is adjacent to the top of the multi-ramp whip-stock. The mill is attached to the whip-stock using the attachment/break bolt, ‘The hydraulic connector is made-up to the bottom of the mill on one end and to a port in the whip-stock on the other end ‘The assembly is lowered into the hole to gain access tothe top of the running tool, The system is filled with clean oil and the setting piston is installed. The flow control sub is made up to the running tool (spaced out if desired) and lowered. The re- maining tubular joints are then made up as needed, with an MID that is aligned with the face of the whip-stock. 787 SIDETRACKING IN A SINGLE TRIP 3 The complete system is lowered to the setting depth, The ‘mud pumps are started and circulation is sustained at 2 rate suitable for receiving feedback from the MWD. Surveys from the MWD are used to obtain the proper orientation of the whipface. Once proper orientation is achieved, the flow con- trol valve is closed and the anchor is hydraulically set. Ten- sion is then pulled on the drill string until the attach- ‘menvbreak bolt fails. This also opens a port for mud circula- tion, which is used for cleaning and cooling the mill and for lifting the cuttings to the surface, ‘The system is now ready to mill the window. While rotating with mud pumps on, the drill string is lowered until it starts to pick up weight. Light weight is used at first to allow for effi- cient cut out of the lead mill. As milling progresses, weight ‘can be increased to obtain 2 good milling rate, Once the win- dow is milled (Fig. 8) and the desired rat hole is drilled (Fig. 9), the mill is pulled out of the hole. The sidetracked wellbore is now ready to be entered with a full gage directional drilling assembly. Technical Innovations Flow Switch, The flow switch is a device that allows for ci culation of uid through the drill string for operation of the MWD without setting the anchor, if itis hydraulic set. With the information from the MWD surveys, the whipface can be properly oriented prior to setting. Flow switches can come in various forms. The shear pin device, the indexing sleeve de- ‘vice, etc. all contain ports that allow drilling fuid to flow from. the drill string to the annulus without over pressuring the hy- draulic set anchor setting mechanism. When the sleeve within these tools is activated to the closed positon, the drill sting can then be pressured to set the anchor. Running Tool. The running tool is used to prevent drilling {uid from contaminating the setting mechanism of the anchor. It contains a piston that preserves clean oil below and keeps the drilling fluid above. Upon setting, the piston strokes downward until the anchor is completely set. Once the mill is pulled from the whip-stock assembly and circulation begins, the piston locates itself in a position such that drilling fluid may by-pass and be circulated through the mil. Milling Tool. The mill incorporates three mili, all of which are full gage mills. The lead mill includes a somewhat short age section at the top and a conical shape nose below to ‘match wit the whip-stock surface. The mill also incorporates multiple circulation ports with breakaway caps that allow full flow circulation once the attachment’break bolt is broken and, milling is stated. The breakaway caps are protected during the trip into the hole so that the integrity ofthe clean hydraulic oil system is maintained until the anchor i set. ‘The follow mill, spaced strategically above the lead mill corporates a teerdrop shape and is designed to further elongate the window as progress is made. ‘The dress mill, located above the follow mill, resembles a4 GREG MILLER, CHARLES DEWEY, JAMES SAYLOR watermelon mill design and includes carbide dressing to smooth or dress off the window profile. Since the lead mill isa fall gage mi 2 shor rat hole if desired. WhipStock. Unlike conventional whip-stocks, the face of the one-trip whip-stock includes multiple ramps with different tapers, A radical ramp is located at the top of the whip-stock to allow for mill hook-up and to expedite the initial engage- ‘ment with the casing. The ramp is followed by a straight sur- face (no taper), allowing trouble-free progress of the mill as- sembly. Below the straight section, a conventional low angle ramp is, used to further deflect the mills toward the formation. Finally a mid-ramp accelerator (radical departure) is in- cluded which, when the mill's center is adjacent to the casing wall, defects the mill more expediently into the formation, Hardmetal application was eliminated from the whipface ddue to heat treatment of the whip-stock. Bottom Hole Assembly Program. This computer program was initially developed to calculate bending stresses in the bottom hole drilling assembly depending upon the hole cur- vature, formation characteristics and various stabilization points. The program was used effectively to optimize the lo- cations of the three mills depending upon the resulting bend- ing characteristics of the mill shaft and the loading of the mill connection. The program also allows for the examination of the angle building tendencies in stiff assemblies (drill collars) verses limber assemblies (drill pipe). The drill collars or drill pipe are run above the milling assembly. ‘When milling a window and drilling a rat hole, different BHA’s can be run depending on what the next drilling assem- bly is supposed to achieve. Short radius drilling assemblies can use a limber milling assembly and a short rat hole, If short radius departure is not required, a stiffer milling assem- bly can be used, and a longer rat hole drilled Hydraulics Program. The hydraulics program was origi- rally developed for drilling tools. It calculates the pressure drop throughout the system and analyzes the standpipe pres- sure depending upon the flow rate and vise versa. ‘The one-trip system performs best with optimum flow rates uring the milling and drilling operations. For this reason, the program was used to study the pressure distribution and the hole cleaning characteristics of the entire system. It is recommended that the program be utilized on all future jobs for optimum jet sizing depending upon the rig’s capabil- ity itallows the drilling of Conclusion ‘The performance during testing of the one-trip sidetracking system met all the objectives set forth before the beginning of the project. Field application of the system has begun and further refinements will occur as input is evaluated. 788 ONE-TRIP SIDETRACKING SYSTEM Fig — DRILL COLLAR ~ ORIENTING SUB MILL ASSEMBLY ;— WHIP-STOCK ~ ANCHORSPE GREG MILLER, CHARLES DEWEY, JAMES SAYLOR SHEAR- OFF BEGIN MILLING FiguRe2 FIGURE 4 CIRCULATE, LENGTHENING CUT OUT yonauue Seneenow ware warsTock FIGURE 3 FIGURE 5 7896 GREG MILLER, CHARLES DEWEY, JAMES SAYLOR SPE ‘CONTINUE MILLING FINISH THE WINDOW | | rouRE® PUSHING ACROSS CENTER FIGURESPE GREG MILLER, CHARLES DEWEY, JAMES SAYLOR ONE-TRIP SIDETRACKING SYSTEM DRILL COLLAR ORIENTING SUB —}— MILL ASSEMBLY }— WHIP-STOCK —;— ANCHOR FIGURE 9 791 PROCEDURE 4.- RUN IN HOLE 2.- ORIENT WHIP-STOCK 3.- SET ANCHOR 4.- SHEAR-OFF 5.- MILL WINDOW 6.- DRILL RAT HOLE 7.- PULL OUT OF HOLE BENEFITS + ELIMINATE STARTER MILL RUN. * AGRESSIVE INITIAL RAMP TO INSURE QUICK EFFICIENT CUT OUT. * ENHANCED CUTTER TECHNOLOGY FOR CONSISTANT MILLING PERFORMANCE. + MID WHIP RAMP. TO REDUCE CORE PROBLEMS AND MILLING TIME. * FULL GAGE MILLS TO ENSURE FULL GAGE RAT HOLE. + ENTIRE PROCEDURE IS FINISHED IN ONE TRIP INTO THE HOLE.