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Section Mill - D Type
Section Mill - D Type
Introduction
The Model D™ Section Mill is a hydraulically
operated Section Mill, primarily designed to mill a
section of casing to permit a sidetracking opera-
tion. It may also be used to mill perforated zones in
oil strings, mill a section of old casing to allow ce-
ment bonding between new smaller casing and the
formation or can be used as a single string casing
cutter.
Features/Benefits
• Operates hydraulically for fast, efficient down-
hole milling
• Knife design reduces long stringers and mills
casing in short chips for easy lift and removal by
the drilling fluid
• All knives are used for initial cutout, reducing
cutout time and minimizing the chance of bent
or broken knives
• Knives are dressed with inserts utilizing
METAL MUNCHER® technology for faster
milling and increased life
This document is and contains unpublished, copyrighted and confidential information of Baker Hughes, and is revealed for limited purposes only. This document
is the property of Baker Hughes and is to be returned to Baker Hughes on request and may not be reproduced, used or disclosed to persons not having a need to
know consistent with the purpose of the document, without the written consent of Baker Hughes. This document is not rented, loaned or sold, either alone or in
conjunction with equipment or product. © 9/23/03 Baker Hughes Incorporated.
Unit No. 4507 10-1-03 Model D™ Section Mill
Rev. B Page 2 of 17
WARNING
Use of Baker equipment contrary to
manufacturer’s specification may result in
property damage, serious injury or fatality.
Specification Guide
H150-72-4500 & H150-72-4502
Casing Tool Weight Casing Max Blade Drift Stabilizer Stabilizer
Clearance
OD OD per Foot ID Expansion Diameter OD Material No.
14.00 5.012 0.497 4.887 4.872 H09-41487-00
15.50 4.950 0.435 4.825 4.810 H09-41487-01
5-1/2" 4.500 17.00 4.892 6.625 0.377 4.767 4.752 H09-41487-02
20.00 4.778 0.263 4.653 4.638 H09-41487-03
23.00 4.670 0.155 4.545 4.530 H09-41487-04
H150-72-5500
Casing Tool Weight Casing Max Blade Drift Stabilizer Stabilizer
Clearance
OD OD per Foot ID Expansion Diameter OD Material No.
17.00 6.538 1.023 6.413 6.398 H09-45140-02
20.00 6.456 0.941 6.331 6.316 H09-45140-03
23.00 6.366 0.851 6.241 6.226 H09-45140-04
7" 5.500 26.00 6.276 8.250 0.761 6.151 6.136 H09-45140-05
29.00 6.184 0.669 6.059 6.044 H09-45140-00
32.00 6.094 0.579 5.969 5.954 H09-45140-06
35.00 6.004 0.489 5.879 5.864 H09-45140-01
H150-72-6250
Casing Tool Weight Casing Max Blade Drift Stabilizer Stabilizer
Clearance
OD OD per Foot ID Expansion Diameter OD Material No.
24.00 7.025 0.760 6.900 6.885 H09-47213-00
26.40 6.969 0.704 6.844 6.829 H09-47213-01
7-5/8" 6.250 9.000
29.70 6.875 0.610 6.750 6.735 H09-47213-02
33.70 6.765 0.500 6.640 6.625 H09-47213-03
Plot the metal cut versus the metal weighed at the Mill for 3 to 5 feet, then continue to rotate while
surface. Significant difference in weights indicate stopping the pumps and picking up off the casing.
hole cleaning problem. Wait a few moments to allow the pressure across
Pills the piston to equalize. Stop rotation and pick up
into the casing above the cut point. Pressure up
Spotted in casing prior to running whipstock and slack off into the window. This should again
and washing over the liner. MMH, Crosslinked give the decrease in standpipe pressure which
Polymer or Bio-Polymers, BHT and milling/drilling proves the blades to be completely opened and
fluid information of project needs to be known prior should also remove any long string shavings which
to recommendation of pills for compatibility study. may have wrapped around the tool during the cut-
DISCLAIMER: These properties are based on years of out. Continue milling.
milling experience. The final say will still be that of The
Mud Company on location. If at anytime there is an increase in rotating
torque, standpipe pressure or a decrease in re-
Operation turns stop milling. This may indicate a “bird nest” of
cuttings accumulating at the top of the section. Pull
Function test Section Mill at surface. Take note back into the casing, reaming as required. Circu-
of the strokes per minute required to fully extend late inside the casing until full returns are restored
the knives into the open position. before mill is lowered into the window. Once the
mill is in the window, ream as required to obtain
Tie back the knives with seezing wire prior to
proper free rotating torque before milling is re-
trip in hole. This will reduce the risk of the knifes
sumed.
hanging up in casing couplings. If a float sub is run,
fill up the work string pipe during TIH with a fill up If torque build-up begins, milling torque cannot
line or without screwing the kelly or top drive into be maintained or the section is complete, shut off
the work string. This will decrease the risk of open- the pump. Now carefully pull the tool up into the
ing the knives. TIH to the proposed bottom of the casing. Use care because the knives may stick in
window, then pull back to the cut out depth. the open position or the tool may be wrapped with
cuttings, in either case, lower the tool 5 to 10 feet
Establish the following parameters, without
into the window and rotate at high speed alternate-
pumping, in the area of the initial cut:
ly with and without the pump. This should remove
• Pick up weight any cuttings, if not ream as required to pull mill
• Slack off weight back into the casing.
• Free rotating torque at the recommended When the tool has been removed from the well,
cutting speed. check thoroughly for damage and percentage of
Initial cut out should be made approximately 2 knife wear and document both.
feet above a casing collar. This will minimize the
risk of backing off a small piece of casing. At the Re-Running The Tool
cutting depth, start the rotary and bring it as close
If you plan to re-run the tool you may remove
as possible to the recommended RPM. Start the
the top sub and take out the indicator. This is a
pump and bring the pump strokes up to the number
matter of personal preference. Some supervisors
required to give a minimum pressure drop of 400
prefer to leave the indicator in place to assist their
psi across the mandrel nozzle. During the cut-out,
judgment during a re-run, others prefer to remove
slack off approximately one inch in increments of
the indicator to prevent washing of its orifice.
1/16" to 1/8" over an interval of 15 to 20 minutes.
At this point, you should have a definite pressure Before re-running the tool, remove the top sub
drop on the gage of about 200 psi. The 200 psi and indicator, then check the top of the mandrel for
pressure drop indicates that you have cut through washing and any obstructions, such as pieces of
the casing and may now start the actual section pump piston rubber. If any washing has occurred,
milling. the washed piece should be replaced and damag-
es documented. Lubricate the threads and re-in-
Adjust pump strokes to accommodate a mini-
stall the top sub (and indicator if desired).
mum 110’ annular velocity.
Unit No. 4507 10-1-03 Model D™ Section Mill
Rev. B Page 6 of 17
Remove one of the six bearing block keeper Perform a magnetic partial inspection, as per
screws; then remove the bearing block keeper. API RP5A5, on all transition areas such as a
Push the knife and bearing up and out of the body. change in OD, knife pockets, set screw holes and
Repeat procedure for each knife. Reverse this pin holes. Perform a magnetic partial inspection on
method to replace the knives. the stabilizer sleeve.
Disassembly Of The Tool Repair or replace any parts having cracks ex-
1. Secure the tool in an appropriate vise; fasten ceeding 3/16" in depth.
the vise on the body between the Top Sub (1)
Cracks where the depth cannot be verified
and the Keepers (16).
should be ground out and filled.
2. Remove the Set Screws (26) which are visible
through the holes in the Stabilizer Rib (25). Re-Assembly Of The Tool
3. Unscrew the Bottom Sub (27). 1. Lubricate all (thoroughly cleaned) parts with a
4. Slide the Stabilizer Rib (25) off the Body (12). good grade lightweight grease.
5. Remove the Hex Socket Cap Screws (15). 2. Secure the Body (12) between the external
6. Remove the Keepers (16). If necessary screw threads and knife windows in an appropriate
a long cap screw into the tapped holes in the vise.
keeper to aid in removal. 3. Dress the Mandrel (22) with the appropriate Bit
7. Push the Knives (18 and 19) toward the Top Nozzle (21), the Nozzle O-ring (20), and Re-
Sub (1) until the Knife Bearings (28 & 29 on 4- tainer Ring (23).
1/2 & 13-3/8, 28 on 5-1/2 - 9-3/4 tools) clear the 4. Insert the Mandrel (22) into the tool from the
T-slot; lift out as a unit, the knife, the knife bear- stabilizer end.
ing, and the pin. The knife bearing now comes 5. Place a small board or some similar object
apart to permit removal of the Pin (17). through the knife windows to retain the Mandrel
8. Unscrew the Top Sub (1) and remove the Pres- (22) in place as far as it will go until you make
sure Indicator (3). up the Piston (11).
9. Remove the three Pressure Plugs (6) from the 6. Place the Spring (14) in the piston bore of the
Piston Cap Retainer (5) and rotate it to remove Body (12).
the Steel Balls (7). 7. Dress the Piston (11) with O-ring (13) and
10.Remove the Piston Cap Retainer (5) from the Packing (10) and push it over the Mandrel (22)
Mandrel (22). until the threads are visible on the Mandrel.
11.Unscrew the Piston Cap (9); remove the Piston 8. Place the Packing Spacer (29 on 5-1/2 thru 8-
(11) and Spring (14). 1/4 tools) behind the Packing (10) on the Piston
12.Remove the packing spacer and packing from (11).
the Piston (11). 9. Screw the Piston Cap (9) onto the Mandrel (22)
13.Push the Mandrel (22) out of the bottom on the and tighten. Remove the small board or other
Body (12). object used to hold the Mandrel in place.
14.Remove the Bit Nozzle (21) from the Mandrel 10.Place the Piston Cap Retainer (5) over the
(22). Mandrel (22) and align it to the groove in the
15.Remove the O-rings (20), (13), (8) from inside Mandrel.
the Mandrel (22) and Piston (11) and outside 11.Tighten two of the pressure plugs in the Piston
the Body (12). Cap Retainer (5) then drop the Steel Balls (7)
16.Thoroughly clean all parts for inspection. through the third hole.
12.When all Steel Balls (7) are in place tighten the
Inspection third pipe plug to secure the balls.
Inspect all API Tool Joints connections in ac- 13.On the 4-1/2 and 11-1/2 OD tools, place the
cordance with API RP 7G. Knife Pin (17) in each Knife (18 and 19) and
cover with both halves of the Knife Bearing (28
Model D™ Section Mill Unit No. 4507 10-1-03
Rev. B Page 7 of 17
and 29). The 5-1/2" thru 9-3/4" OD tools have a Useful Formulas:
one piece Knife Bearings (28). On these tools,
Optimum Cutter surface speed to RPM:
place the Knife (28 and 29) in the Knife Bearing
(28) and insert the Pin (17). R = So / (D x 3.14/12)
14.Slide the Knife and Bearing assembly in the T- So= Optimum surface speed
slot of the Body (12) until the keeper will fit be- D = Maximum blade expansion
hind the Knife Bearing. R = Rotary speed RPM
15.Install the keeper Hex Socket Cap Screw (15). Example: to cut 5-1/2 Casing with Metal Muncher
16.Repeat steps 15 and 16 until you have secured inserts with an optimum surface speed of 250 feet
all the knives in the tool. per minute:
17.Slide the appropriate Stabilizer Rib (25) onto 250 / (6.625 x 3.14 / 12) = 144 RPM
the Body (12).
18.Screw the Bottom Sub (27) onto the tool and Pressure Drop Across an Orifice
tighten it in place. P = (G2D) / (12031A2C2)
19.Lock the Bottom Sub (27) with Hex Socket Set P = Pressure Drop
Screws (26). G = Circulating Rate in Gallons per minute
20.The tool can now be function tested. D = Fluid Density (mud weight in ponds per gallon)
A = Area of nozzle in inches2
Stand the tool upright and drop a ball which will C = Nozzle coefficient
seat on the top of the mandrel. Screw test plug into
the top sub and apply air pressure. The knifes Example: 8-1/4 Section Mill with a 3/4" nozzle in
should now be forced out to the maximum expan- the indicator and a 1" nozzle in the mandrel. Circu-
sion (this may be checked with a ring gauge). lating at 400 GPM with 10 lb/gal mud, using a noz-
zle coefficient of .95.
21.Back off the Top Sub and remove test ball.
Place the Indicator in the Top Sub, the O-ring in Pressure Drop At Indicator:
the groove of the Body Threads then tighten the
Top Sub on the Body. P = (G2D) / (12031A2C2)
22.Wrap a tight wire around the Body in the groove P = (4002 x 10) / (12031 x .44152 x .952)
over the Knives to hold them in place for run- P = (160,000 x 10) / (12031 x .1949 x .9025)
ning in the hole (or shipping). P = 1,600,000 / 2,116
P = 756 psi
Recommended Makeup Torque
Pressure Drop at Mandrel:
Values for Grade 5 Cap Screws/Bolts
P = (G2D) / (12031A2C2)
Torque (Ft-Lbs)
P = (4002 x 10) / (12031 x .7852 x .952)
Cap Screw
Size (In)
Coarse Fine P = (160,000 x 10) / (12031 x .6162 x .9025)
10-32 5 6 P = 1,600,000 / 6,690
1/4 10 11 P = 239 psi
5/16 20 22 Gallons Per Minute Required for desired
3/8 36 40 pressure drop:
7/16 57 64
1/2 90 100 G= P(12031A2C2/D)
9/16 125 140 G = Circulating Rate in Gallons per minute
5/8 175 200 P = Pressure Drop
3/4 310 340 D = Fluid Density (mud weight in ponds per gallon)
7/8 500 550 A = Area of nozzle in inches2
1 740 810 C = Nozzle coefficient
1-1/8 930 1,040
1-1/4 1,300 1,440 Example: A 400 psi pressure drop is required to
1-3/8 1,700 1,900 cut out with an 8-1/4 Section Mill with a 3/4" nozzle
1-1/2 2,270 2,550 in the indicator and a 1" nozzle in the mandrel. The
Unit No. 4507 10-1-03 Model D™ Section Mill
Rev. B Page 8 of 17
Rev. B
Unit No. 4507
Page 9 of 17
10-1-03
Unit No. 4507 10-1-03 Model D™ Section Mill
Rev. B Page 10 of 17
Rev. B
Unit No. 4507
Page 11 of 17
10-1-03
Unit No. 4507 10-1-03 Model D™ Section Mill
Rev. B Page 12 of 17
Rev. B
Unit No. 4507
Assembly And Dimensional Data Drawing No. 947-207
Page 14 of 17
10-1-03
Model D™ Section Mill
Model D™ Section Mill Unit No. 4507 10-1-03
Rev. B Page 15 of 17
Rev. B
Unit No. 4507
Assembly And Dimensional Data Drawing No. 947-208
Page 16 of 17
10-1-03
Model D™ Section Mill
Model D™ Section Mill Unit No. 4507 10-1-03
Rev. B Page 17 of 17