Sir William Smith Road, Kirkton Industrial Estate,

Arbroath, Angus, Scotland, U.K. DD11 3RD

Tel: +44 (0) 1241 877776. Fax: +44 (0) 1241 871037
E-mail: sales@pioneeroiltools.com
Website: www.pioneeroiltools.com

‘SM’ SECTION MILL

OPERATIONS MANUAL

SM OM 06/09 Copyright 2009

D001190640 (A.1) PMTD: Stewart, Rik 2022-06-14
 ‘SM’ SECTION MILL

Index

Page 2 - Introduction

Page 4 - Disassembly Procedure

Page 7 - Maintenance Procedure

Page 9 - Assembly Procedure

Page 12 - Operation Procedure

Tables

Page 3 - Milling Arm Selection Chart

Page 14 - Operational Flow Rates

Page 15 - Make-up Torque Values

Page 15 - Operating Parameters

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 ‘SM’ SECTION MILL

INTRODUCTION

The PIONEER ‘SM’ series is a

simple yet rugged design. The primary use
is that of milling out casing and tubing
sections. The ‘SM’ tool is hydraulically
operated for fast and simple downhole
milling operations.
The opening cut is made by simply
rotating the string and increasing the pump Top Sub
strokes to give the required pressure drop
across the piston choke. An important
feature is the Flotel Assembly which, when
Body
the arms are fully extended, will reflect a
drop in pump pressure. This gives a
positive indication that the opening cut is
complete. Pump pressure is then increased Flotel Assembly
until the annular velocity is sufficient to
clear mill cuttings out of the hole.
Standard ‘SM’ assemblies are equipped
with jetting nozzles in the Top Sub; these
Piston
nozzles assist the removal of mill cuttings
resulting in greater efficiency and milling
arm longevity.
Arm Socket
Proceed with milling the section of
casing required by continuing rotation
Long Milling Arm
whilst increasing the WOM. The optimal
RPM and WOM can be determined after Short Milling Arm
careful consideration of the casing
variables involved such as casing size,
casing grade etc. Arm Stop Stabiliser
Once the required section has been
milled simply stop the pumps. This allows
the Piston to return thus permitting the
Arms free to collapse, the tool can then be
pulled out of the hole.

fig 1.

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 ‘SM’ SECTION MILL
Pioneer ‘SM’ series SECTION MILL Milling Arm Selection Chart
Section Qty. Qty. Milling
Mill Tool Tool Tubing/Casing
Long Milling Arm per Short Milling Arm Per Arm Max
Assembly OD Length Size Part No. Tool Part No. Tool Sweep
SM0363-03 3 N/A -
SM0363B 3.5/8” 74.8” 4.1/2”-5” 5.38”
SM0363A-03 3 N/A -
SM0413-03 3 SM0413-04 3
SM0413B 4.1/8” 65.5” 5” 6.12”
SM0413A-03 3 SM0413A-04 3
SM0450-03 3 SM0450-04 3
SM0450B 4.1/2” 76.0” 5.1/2” 6.63”
SM0450A-03 3 SM0450A-04 3
SM0550-03(7”) 3 SM0550-04(7”) 3
7” 8.25”
SM0550B 5.1/2” SM0550A-03(7”) 3 SM0550A-04(7”) 3
84.0”
SM0575B 5.3/4”

Table 1
SM0550-03(7.5/8”) 3 SM0550-04(7.5/8”) 3
7.5/8” 8.75”
SM0550A-03(7.5/8”) 3 SM0550A-04(7.5/8”) 3
SM0825-03(9.5/8”) 3 SM0825-04(9.5/8”) 3
3.

9.5/8”-10.3/4” 12.25”
SM0825A-03(9.5/8”) 3 SM0825A-04(9.5/8”) 3
SM0825B 8.1/4” 102.5”
SM0825-03(10.3/4”) 3 SM0825-04(10.3/4”) 3
10.3/4”-11.1/2” 13.38”
SM0825A-03(10.3/4”) 3 SM0825A-04(10.3/4”) 3
SM1150-03(13.3/8”) 4 SM1150-04(13.3/8”) 4
13.3/8” 16.75”
SM1150A-03(13.3/8”) 4 SM1150A-04(13.3/8”) 4
SM1150B 11.1/2” SM1150-03(16”) 4 SM1150-04(16”) 4
103.3” 16” 19.00”
SM1175B 11.3/4” SM1150A-03(16”) 4 SM1150A-04(16”) 4
SM1150-03(18.5/8”) 4 SM1150-04(18.5/8”) 4
18.5/8” 21.71”
SM1150A-03(18.5/8”) 4 SM1150A-04(18.5/8”) 4
Notes: Milling Arm part numbers SM****-03 or 04 are dressed with a Tungsten Carbide matrix.
Milling Arm part numbers SM****A-03 or 04 are dressed with Tungsten Carbide inserts.
Other assembly sizes available.

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 ‘SM’ SECTION MILL

fig. 2

fig. 3 fig. 4

DISASSEMBLY PROCEDURE

• Remove the jetting nozzles from the top sub (if applicable) using a jetting nozzle key (fig. 2).

• Break out the connection between the top sub and main body, this is best done using a service unit
designed to make and break tool joint connections. Remove the top sub and lay it aside.

• Secure the main body in a suitable vice, clamping on the upper end (fig. 3) ensure that the body lower
end is adequately supported with both ends freely accessible.

• Unscrew each of the 3 off flotel lockscrews using a suitable hex pin soc wrench set-up (fig. 4).
5 turns per screw will release the flotel assembly allowing the assembly to be pulled free from body.
Note: do not remove the flotel lockscrews at this stage.

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 ‘SM’ SECTION MILL

fig. 5 fig. 6

fig. 7 fig. 8

DISASSEMBLY PROCEDURE Cont.

• Remove the arm stop stabilizer retaining screws using an appropriate size hex key (fig. 5).

• Remove all the arm stop stabilizers in turn and lay aside (fig. 6).

• Remove the milling arm pin retaining screws using an appropriate size hex key (fig. 7).

• Use a suitable punch/rod, knock out and remove the milling arm pin holding the arm in place
(fig. 8). Caution: once the pin is removed, the milling arm is then unconstrained and
consequently if allowed to fall free from its slot may cause damage or injury. Lift the milling arm
free of the body slot and lay aside. Repeat this sequence until all of the arms are removed.

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 ‘SM’ SECTION MILL

DISASSEMBLY PROCEDURE Cont.

At this point the piston spring must be compressed to relieve the spring force acting on the arm
sockets via the piston nose. A safe method to compress the spring should be adopted; an example
method is show below (fig. 9).
The use of a threaded rod through the bore used in conjunction with two appropriate sized
plates/bungs allows the piston spring to be compressed by simply screwing the nut down the
threaded rod.

fig. 9

DO NOT REMOVE THE ARM SOCKETS UNTIL THE

PISTON SPRING FORCE HAS BEEN RELIEVED.
Once the piston spring force is no longer acting on the arm
sockets, the screws and arm sockets may be removed (fig. 10).
Carefully release the piston spring compression and remove the
piston assembly from the body and lay aside.

fig. 10

Finally unclamp the body and safely lay aside.

Once fully disassembled perform recommended maintenance operations.

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 ‘SM’ SECTION MILL

MAINTENANCE PROCEDURE
Thoroughly clean all disassembled components prior to inspection.

Body Maintenance:

• Inspect internal, external and slot surfaces for damage or wear. Light scratches to the piston-sealing
bore may be dressed using fine emery. Burrs and rough areas on the outside diameter may be dressed
using a suitable file; burrs, nicks or gouges of the slot edges and faces may also be dressed using a
suitable file. Note: care should be taken to ensure that the edges of the slots are not enlarged during
this process; enlarged slots may be detrimental to milling arm efficiency and longevity.

Seal-Retaining Ring Piston Seal O’ring

Piston Body

External
Circlip

Internal
Circlip

Choke

Gripping Point

Fig. 11

Piston Maintenance:

• Grip the piston assembly in a suitable vice immediately behind the upset diameter (fig. 11).
• Remove the internal circlip by using a pair of appropriate internal circlip pliers.
• Remove the carbide choke, inspect for signs of undue wear or cracks. Undue wear or cracking are
cause for replacement.
• Remove the internal o’ring. Lightly grease and re-assemble with a new o’ring & circlip.
• Remove the external circlip using a pair of appropriate external circlip pliers.
• Remove the piston seal-retaining ring and piston seal.
• Lightly grease and install a new piston seal, assemble the seal-retaining ring against the seal and
secure in position using a new circlip where possible.

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 ‘SM’ SECTION MILL

MAINTENANCE PROCEDURE Cont.

Flotel Circlip
Body Ball
Bearing
Locking
Screws Carbide
Flotel Stem
Shaft
Spacer

Conical
Nut

Caution: DO NOT
CLAMP/GRIP HERE!

Fig. 12

Flotel Maintenance:
See cautionary note regarding clamping (fig. 12)
• Remove the circlip on the flotel assembly (fig. 12) by using an appropriate pair of thin nose pliers or
a small bladed screwdriver to splay the gap. When the circlip is removed the 3 balls are free to fall
loose; appropriate steps should be taken to catch them and prevent loss.
• If possible replace with a new circlip.
• Inspect the carbide stem for undue wear or cracks. Undue wear or cracks are cause for rejection and
factory refurbishment is advisable.

Remaining Components:

• Inspect arm stop stabilizers, arm sockets and milling arm pins for wear/damage. Any signs of
wear/damage are cause for replacement.
• Inspect jetting nozzles (if applicable) for undue wear or cracks. Undue wear or cracks are cause for
replacement.
• Replace all jetting nozzle o’rings (if applicable).

Marshall all components in a safe area, ensure lightly greased/oiled to protect surfaces.

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 ‘SM’ SECTION MILL

ASSEMBLY PROCEDURE

fig. 13

fig. 14 fig. 15

• Secure the main body in a suitable vice clamping on the upper end (fig. 13) ensure that the body
lower end is adequately supported with both ends freely accessible.
• Liberally grease the piston assembly and slide it into the body (fig. 14). Note: ensure that the
assembly remains centralised during this installation, otherwise the piston face and/or seal may
conflict with the body recess lip.
• At this point the piston must be compressed to allow the arm sockets to be installed. A suitable
safe method is as previously described on Page 6 – paragraph 1 (Fig. 9)
• Once the piston spring has been compressed sufficiently to allow correct arm socket positioning,
insert the arm socket (fig. 15) and hand tighten both securing cap screws, repeat this process to
install the remaining arm sockets; torque tighten each cap screw in turn to the specified value as
indicated in the corresponding column table 3 page 14. Note: the arm sockets act as a stop for
the piston travel. Slowly release the spring until the force is acting on the arm sockets.

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 ‘SM’ SECTION MILL

ASSEMBLY PROCEDURE Cont.

fig. 16 fig. 17

fig. 18 fig. 19

• Ensure that the flotel lockscrews are backed off by approx 5 full turns with the circlip having
slight free play. Liberally grease the outside diameter of the flotel assembly (fig. 16). Insert the
assembly into the body and locate the outside diameter into the mating body recess. Slide the
assembly forward until it firmly seats on the body shoulder.

• Make-up the 3 off flotel lockscrews using a suitable hex pin wrench (fig. 17), thus locking the
flotel assembly in position. Firmly hand tighten each screw in turn.

• Locate a milling arm pin into its corresponding hole in the body, offer the milling arm into the
body slot and push forward until located in the arm socket (fig. 18).

• Drive the pin through the milling arm until it hits its shoulder stop, a pin punch is best suited for
this operation (fig. 19). Check the milling arm for free rotation. Repeat this process to install all
the remaining milling arms.

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 ‘SM’ SECTION MILL

ASSEMBLY PROCEDURE Cont.

fig. 20 fig. 21

fig. 22

• Insert the milling arm pin lock screws (fig. 20) and tighten to the torque value specified in the
corresponding column in table 3 on page 14.

• Insert the arm stop stabilizers into the body slots (fig. 21), install the retaining screws and tighten to
the torque value specified in the corresponding column in table 3 on page 14.

• Grease the top sub internal pin thread and make-up to the body. See the corresponding column in
table 3 on page 14 for the required torque value.

• Insert the o’rings and the jetting nozzles into the top sub (if applicable), lightly grease/oil the o’ring
prior to insertion, use the jetting nozzle key to firmly hand tighten (fig. 22).

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 ‘SM’ SECTION MILL

OPERATION PROCEDURE
RUNNING IN THE HOLE:

• Ensure both connections of section mill are fitted with thread protectors prior to moving the tool.
• Make-up and RIH the lower components of the string to the point where the section mill would be
connected and set in the slips.
• Lift the section mill over the rotary table and make-up to the lower string.
• Test the section mill at surface to determine the flow rate to extend the milling arms.
• Secure the milling arms before RIH.
• Make-up the upper string components to the section mill and RIH.

MAKING THE OPENING CUT:

• RIH past the section that is to be cut to insure that the section mill will pass through the entire
section to be cut.
• Pick back up the section mill to the top of the section, laying down excess drill pipe. Make-up the
swivel and start circulation with enough flow rate to extend the milling arms.
• The point of the first cut is very important; it is NOT to be just below a casing collar, as the upper
piece might back off. Using enough pump pressure to hold the milling arms against the casing
wall, slowly lower until the milling arms stop against a casing collar. Caution: apply as little
weight as possible during this stage. After locating the collar pick-up 1.5-2.0 metres and stop
circulating.
• Start rotating at calculated RPM (table 3 on page 14). Note free torque and string weight before
starting the pumps.
• Start circulation and slowly increase the pump pressure from idle until excess torque is noticed.
Continue to increase the pressure to make the opening cut, an approximate guide to the opening
cut flow rates are in table 2 on page 13. Continue the opening cut until free torque and a pressure
drop indicate the opening cut is complete.
• Set circulation at the milling flow rate, determined from the table 2 on page 13. Mill one metre of
casing (see RPM & WOM in table 4 on page 14 for milling parameters). Pick-up by 0.3 metres
and then stop rotation and circulation.
• Pick-up above the point of the opening cut, begin circulation at the milling flow rate. DO NOT
ROTATE. Lower the string until the milling arms take the weight at the point where milling
stopped. Apply 1.5 times the WOM to confirm casing has been milled not “skimmed”.
• Stop circulation and pick-up by 0.3 metres.

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 ‘SM’ SECTION MILL

OPERATION PROCEDURE Cont.

MILLING THE SECTION:

• Start circulation and rotation as per milling parameters.

• Resume milling at one metre per hour ROP using as little WOM as possible to minimize milling
arm damage/wear. Note do not exceed the maximum WOM as per table 4 on page 14.
• After every one metre of progress a Hi-Vis sweep should be circulated to clear any
cuttings/particles that may of built up.
• Take notice of any pressure increase, which may indicate a birdnest is forming. If a birdsnest is
suspected, work the string up and down while continuing to rotate until pressure returns to normal.
CAUTION not to pull the mill into the upper stub with the knives in the locked out position.
• The returns should be checked frequently to ensure adequate cuttings are returning.
• Continually monitor the shale shaker, trough and flowline for plugging/blocking up; a system for
jetting the flowline should be in place to avoid having to shut down should the flowline become
plugged/blocked. This is a serious situation; should it occur it could result in a stuck string: jet the
flowline regularly to avoid any possibility of this.
• Once the section is milled to depth, pick-up by 0.3 metres, stop rotation and circulation.

PULLING OUT OF HOLE:

• With the circulation pumps stopped slowly lift the mill into the upper stub, once clear of the upper
stub without any hang-up indication noticed, proceed in pulling the tool to surface.
• Should there be a problem in entering the upper stub, lower the mill into the cut section and
circulate Hi-Vis sweep at milling flow rate, stop circulating again and try entering upper stub.
Following this slow left hand rotation would aid the milling arm collapse whilst trying to enter
upper stub.

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 ‘SM’ SECTION MILL

OPERATING PARAMETERS – FLOW RATES

These flow rates are calculated at the minimum required based on a fluid density of 10lbs/gallon.
All flow rates are in gallons per minute.
These values are a guideline only.

Section Mill Assembly

Table 2 SM0550B SM1150B
SM0363B SM0413B SM0450B SM0825B
SM0575B SM1175B
Number of Jetting Nozzles per Tool 2 2 2 2 3 4
Nozzle
Operation Description Size
Collar location flow rate Blank 24 30 28 33 49 46
Minimum flow rate to
stroke the piston over 12 75 84 78 82 116 130
length of flotel stem with 14 94 104 96 100 140 161
milling arms free to
contact casing bore. 16 115 126 117 121 167 196
Blank 60 86 82 85 138 138
Opening cut flow rate
Minimum flow rate 12 187 242 230 211 327 390
required making opening 14 234 298 285 257 395 481
cut.
16 286 362 346 309 474 586
Blank 93 128 124 163 221 214
Milling flow rate
Minimum flow rate to 12 140 176 169 209 281 291
hold the milling arms in 14 157 192 186 225 302 319
the locked-out position
16 176 212 205 245 327 351
Blank 206 281 281 367 574 574
Flow rate to give jetting
velocity of 150ft/sec when 12 309 384 384 470 729 780
milling arms in locked-out 14 347 422 422 508 785 855
position
16 389 464 464 551 849 941

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 ‘SM’ SECTION MILL

OPERATING PARAMETERS – MAKE-UP TORQUE

These torque values are for assembly purposes, torque required to disassemble may be different.
These values are a guideline only.
All values are pounds force per foot (lbf.ft)

Section Mill Assembly

Table 3 SM0550B SM1150B
SM0363B SM0413B SM0450B SM0825B
SM0575B SM1175B

Arm Socket Retaining Screw 33 33 33 33 144 144

Milling Arm Pin Retaining Screw 5 16 16 16 16 16

Arm Stop Stabilizer Retaining Screw 33 33 33 33 144 144

Top Sub to Body 3,700 9,800 9,100 18,900 38,800 45,000

OPERATING PARAMETERS – MILLING PARAMETERS

Rotational milling speeds are calculated using these optimum surface cutting speeds:
300-350 ft/min for Tungsten Carbide INSERT dressed Milling Arms.
200-220 ft/min for Tungsten Carbide MATRIX dressed Milling Arms.
All rotational speeds are in revs per minute (RPM).
Weight on mill (WOM) is calculated based on casing grade N80.
Operator may change RPM & WOM to suit application for ROP. Note: harder grades of casing may require
less WOM & greater rotational speed to maintain ROP. Never exceed maximum WOM.
Casing Size to be Milled
Table 4
4.1/2” 5” 5.1/2” 7” 7.5/8” 9.5/8” 10.3/4” 13.3/8” 16” 18.5/8”
Recommended RPM
for Tungsten Carbide
INSERT
275 250 225 180 165 130 115 95 80 70
dressed Milling Arms
Recommended RPM
for Tungsten Carbide
MATRIX
180 160 145 115 105 85 75 60 50 45
dressed Milling Arms
Recommended
0.6-0.8 1-2 1-2 2-3 2-3 3-4 3-4 4-5 4-5 4-5
WOM for
milling section Tons Tons Tons Tons Tons Tons Tons Tons Tons Tons
1.6 4 4 6 6 8 8 10 10 10
Maximum WOM
Tons Tons Tons Tons Tons Tons Tons Tons Tons Tons

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15.
 ‘SM’ SECTION MILL

NOTES:

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 Sir William Smith Road, Kirkton Industrial Estate,
Arbroath, Angus, Scotland, U.K. DD11 3RD
Tel: +44 (0) 1241 877776. Fax: +44 (0) 1241 871037
E-mail: sales@pioneeroiltools.com
Website: www.pioneeroiltools.com

‘SM’ SECTION MILL

OPERATIONS MANUAL

As the policy of Pioneer Oil Tools is one of continual product improvement,

SM OM 06/09 we reserve the right to change designs or specifications without notice Copyright 2009
D001190640 (A.1) PMTD: Stewart, Rik 2022-06-14