SECTION MILLING

Introduction
Section Milling is the term given to removing a section
of casing, usually cemented, without disturbing the
casing string above in "cutting a window".

The window can then be used as an exit point to allow

a new hole section to be drilled by kicking off through
the window.

The tools used are commonly known as "section mills"

although they are also used effectively in cutting
casing strings prior to retrieval.
 Introduction

Lessons learnt and techniques developed during

these operations have been recorded for future
reference.

Optimum progress relies on good downhole

milling mechanics (mill cutting characteristics,
BHA, operating parameters) and the efficient
removal of the milled steel cuttings, or swarf.
 Introduction

The cutting of a window will produce substantial

volumes of swarf, the removal of which will
require planning to ensure efficient hole cleaning
and effective collection and disposal on surface.

Section mills are less robust and have much less

cutting structure than casing mills; steel cutting
rates will be lower and run lengths very much
shorter.
 Introduction

However, the form of swarf cut may be finer, less

spiralled, and consequently less prone to tangling.

These factors are influences in the selection of milling

fluids and in determining the extent of modifications
justified in surface handling facilities.

Although the emphasis may be less critical than for

casing milling, the principles remain valid and proper
planning should not be overlooked.
 Selection of Window Interval

Once the approximate position of the window has been

determined, a number of points should be considered in
determining the exact interval.

1. Well status prior to section milling operations. Consult

cement bond logs to assess the degree of casing-cement
bonding over the casing section to be milled. Mechanical
performance will be improved across well cemented
intervals where lateral play is minimised.
 Selection of Window Interval

2. Consult casing string tally to establish position

of casing collars and casing jewellery. The section
to be milled should start either 5 ft above or 15 ft
below a casing collar to avoid the casing backing
off from the coupling. Plan to mill as few casing
collars as possible and finish the window above a
coupling. Couplings typically contain 80 - 120%
more steel per unit length than casing and will
rapidly wear cutting knives.
 Selection of Window Interval

3. Avoid having to mill centralisers if possible. If

this is unavoidable, plan to mill the centralisers at
the beginning of the section before the knives are
dulled. The potential for tool damage is increased
by the lack of restraint on centraliser and stop
collars being able to spin around the casing. Also
they tend to break into larger pieces and can be
difficult to remove.
 Selection of Window Interval

4. Establish contents of annulus fluid and consider

relevant mud weights for section previously
drilled, along with pore pressure, formation
integrity and possible zones for potential
communication.

5. Consider effect of annulus fluids in

contaminating selected milling fluids and required
steps to be taken.
 Selection of Window Interval

6. The ability to effectively rotate the string and

apply milling torque should be assessed by
reference to the drilling simulator programme
(input milling fluid, drillstring and well trajectory
data). The high frictional forces in deep or highly
deviated wells may dictate the use of well
lubricated oil muds.
Selection Milling – Tool Operation
A typical section mill tool is shown
opposite along with its basic design and
operating principles.

Tungsten carbide coated knives are hinge-

pinned to the tool and are hydraulically
actuated to make contact with, and
abrade, the casing wall. Depending on its
size and design, the section mill generally
has 3 or 6 knives.
Selection Milling – Tool Operation
A typical section mill tool is shown opposite
along with its basic design and operating
principles.

Tungsten carbide coated knives are hinge-

pinned to the tool and are hydraulically
actuated to make contact with, and abrade,
the casing wall. Depending on its size and
design, the section mill generally has 3 or 6
knives.
Selection Milling – Tool Operation
The basic operating principle is similar to
that of underreamers.

A downward force is created by the pressure

drop in the circulating fluid as it flows
through an interval nozzle or orifice. The
force acts upon a simple piston/cam
arrangement to open out the knives until
they are wedged into contact with the casing
wall.
Selection Milling – Tool Operation
The maximum cutting circle diameter is
fixed by selecting knives of the required
length or by setting a stop to limit the
opening travel of the knives. Once opened,
most tools allow a portion of the fluid flow
to bypass the nozzle or even directly onto
the face of the knives. The consequent
reduction in pressure drop is a positive
surface indication that the initial cut of the
casing has been completed.
 Swarf Removal & Handling

1. Ideally the majority of the swarf circulated

from the well will be removed in a gumbo
box arrangement situated close to the bell nipple.
However, as this facility will not be available in
most cases, the routing through the primary
solids control equipment will be crucial, especially
the elimination of undesirable swarf traps.
 Swarf Removal & Handling
2. All internal restrictions and instrumentation,
metering devices, etc. should be removed from
the flowline. Sections with potential for swarf
build-up and blockage may need to be
temporarily substituted with open trough
sections. Suitable access points for rodding the
flowline in order to disturb blockages
should be provided. Facility to jet the flowline
may be useful - temporary connection from
header box jetting line.
 Swarf Removal & Handling

3. Returns should be directed to feed into the top

of shaker header boxes, i.e. "top-dumped". If
practical, the lower regions of the box should be
plated off so that the swarf "flows" with the mud
to the shakers and does not build up in the sump.
Do not seal off the sump completely as draining
through the dump valve may be necessary at
some stage.
 Swarf Removal & Handling
4. The arrangement for managing flow to the
shakers may need attention. Thule shakers have
gates which lift up to open a slot and perforated
guide plates, both features tend to trap swarf and
cause it to build up. If not cleared then minor
collections of swarf can become major
accumulations quite quickly. A weir arrangement
is recommended in place of the gates and the
perforations should be covered with thin steel
plate..
 Swarf Removal & Handling

5. Swarf will tend to bind in the mesh of coarse

shaker screens. The finest mesh sizes robust
enough to withstand the duty should be
established quickly. It should be practical to use
40 or 60 mesh screens on the top and 80 or 100
mesh on the bottom.
 Swarf Removal & Handling

6. If the cuttings disposal chute is relatively

straight, has a large bore and a convenient
intersection point, it may be a practical means of
transporting swarf away from the shakers.
However, be cautious: a blocked chute can be
difficult to clear. A means of getting the swarf
from the chute and into skips, and for the regular
changing of skips must be devised.
 Swarf Removal & Handling

7. Measures must be in place to ensure that such

swarf and/or joints of casing and tubing is either
immersed in water (to prevent the oxygenation of
the scale, and must therefore be kept wet
thereafter), or stored in a safe location and
allowed to dry completely.
 Swarf Removal & Handling

8. The bulk volume will vary with the form of

swarf cut, a skip may be physically full before the
allowable load is reached. Weigh a 3/4 full skip on
the crane to test the actual situation. Obviously
sufficient skips will be required to complete the
job or sustain operations until the next scheduled
arrival of a supply vessel. As a minimum, maintain
sufficient skips on board to sustain 4 days milling.
 Swarf Removal & Handling

9. Grating filters or traps should be placed over

drains in the vicinity of the shakers to prevent
swarf entering and blocking the lines.. Ditch
magnets should also be positioned in both
locations, in pairs. If the facility is available, then
mud pump suction strainers should be used -
sized for the largest tolerable drop in delivery
charge pressure. Strainers and magnets must be
checked and cleaned frequently by organising a
planned cleaning schedule.
 Swarf Removal & Handling

10. Milling of long sections of casing results in

large transfers of heat energy into the milling
fluid – high temperatures can be expected.
Efficient fume extraction and ventilation in the
shaker/header box area is required if tolerable
working conditions are to be maintained.
Examine the practicality of improving the natural
ventilation by installing louvres or temporarily
opening up sections of walls.
 Swarf Removal & Handling

11. Small rakes with round-ended tines assist in

moving swarf off the shaker screens. Shovels and
potato digging forks will be required for manual
handling of swarf.

12. Cleaning points should be established at

appropriate locations where swarf can build up
and where mud spillages may occur.
 Swarf Removal & Handling

13. The wear bushing profile should present a

smooth bore through the wellhead to avoid any
tendency for swarf to become trapped and build
up.

14. Unnecessarily functioning BOPs or circulating

through additional equipment and valves should
be avoided in order to minimise potential damage
by swarf to seals and seal areas.
 Swarf Removal & Handling
15. In the interests of subsequent equipment and
drilling fluid maintenance, it is important that all
remaining pieces of milled swarf be removed
from the surface facilities on completion of
operations. The mud pumps, lines and valves
should be fully inspected. In addition to mud lines
and pits, this should include the drip tray, trip
tank, areas around and under the shakers and
places forming natural traps. BOP ram cavities, kill
and choke lines, standpipe and choke manifolds
should be flushed.
 Hole Cleaning Fluids
Oil Based/Water Based Mud
In general, it is recommended that water based
fluids are used. During the milling operation, a
high degree of personnel contact with the fluid
will be unavoidable in clearing birds nests,
collecting and disposing of the swarf. Even with
the appropriate protective clothing, use of an oil
based mud will inevitably result in increased
levels of skin complaints. Additionally, there is an
increased risk of environmental pollution when
milling with oil based mud.
 Hole Cleaning Fluids

Water Based Mud Types

If a water based fluid is used, then consideration
must be given to possible shale inhibition
requirements if the operation will expose water
sensitive formations.
There are several types of water based milling
fluid that can be used. These include:
- Bentonite/XC Polymer
- Bentonite/Sodium Bicarbonate
- Bentonite/Mixed Metal Hydroxide
 Hole Cleaning Fluids

Mud Properties

Mud Weight:

When possible an unweighted system should be

applied if a water based mud is in use as this will
greatly assist logistics. When milling casing across
open hole, the mud weight should be that as
used to initially drill the section.
 Hole Cleaning Fluids

Mud Properties

Rheology:

The following rheological criteria are given as a

guideline:
PV cP < 10
YP lbs/100 sq ft 50 - 70
Gels lbs/100 sq ft 35 – 50
 Hole Cleaning Fluids
Mud Properties

Mud contamination:

Mud contamination by cement from behind the

casing may require substantial additions of Sodium
Bicarbonate to treat the presence of excess Ca
ions. A large quantity of sodium bicarbonate
should be available offshore as a contingency if
required. Consideration to pre-treating the milling
fluid prior to commencement of the milling may
also be required.
 Section Milling Assembly

Efficient operation requires the tool to be

well centralised.
The taper mill and pilot stabilisers should be
the same size as the casing drift diameter.
The section mill body diameter should be
the largest available to comfortably run
inside the casing so that the knives are as
short, and as strong, as possible.
Limit the number of drill collars to that
required to provide the maximum
anticipated milling weight. Jar placement
should be determined for operating effect.
 Section Milling Assembly

Recommended general assemblies (add

crossovers as necessary):

a) Straight Hole:
Taper Mill - Near Bit Stabiliser - Section Mill -
4-6 DC - Jars - 1-2 DC - HWDP.

b) Deviated Hole:
Taper Mill - Near Bit Stabiliser - Short DC -
String Stabiliser – Section Mill - 4-6 DC - Jars -
1-2 DC - HWDP.
 Section Milling Assembly

There is a danger of the connections below

the section mill working loose with
consequent loss of all or part of the pilot
assembly.

"Lock-up“ type connections should be used if

available, otherwise connections should be
made up "dry" and use of a thread-locking
compound considered.
 Operating Procedures
1. Fluid circulation rates through section mills are
limited by the size of the fluid courses and by the knife-
actuating forces developed. If the tool features an
interchangeable nozzle/orifice then the size selected
should be consistent with a flowrate adequate for hole
cleaning purposes.

2. The required diameter of the knife cutting circle will

depend on casing string to cut/mill across an open
hole section. The cut should be positioned 10 -15 feet
below a casing coupling to make best use of the
enforced stand-off between the strings.
 Operating Procedures
3. Sets of knives can vary in shape, excessively high
point-loading could result; check that each set,
including spares, are similar.
Hinge pins do sometimes bend in service; confirm that
spares are available.
If more than one style of tungsten/carrier matrix is
available, confirm that the most suitable is used -
generally the hardest, most resilient category.
4. As with any downhole tools, ensure that all lengths
and dimensions have been recorded before the
assembly is run. Also confirm that suitable fishing tools
are available.
 Operating Procedures
5. Function test the tool at surface. Pump through the
tool at the "cutting-out" flowrate with the knife travel
restricted to the casing ID (if practical) and then fully
opened. Increase circulation to the full milling flowrate.
Record the pressures at each stage, this is useful
information when starting the actual operation.
Check that the knives have opened fully to an even
cutting circle.
6. Pin the knives back into the body with insulating
tape, string or slivers of wood. If left loose, the knives
are prone to hanging up in the wellhead and recesses
in the casing string.
 Operating Procedures

7. Drift the whole drillstring with proper, near-size

rabbits. Loose cement or scale may block the tool or
impair its operation.

8. Run the mill to the bottom of the proposed window

to ensure that the casing bore is clean.

9.Pull back and take string up, down and rotating drags
- without pumps.
 Operating Procedures
10. Attempt to locate a casing collar so that the
window may be accurately positioned.
Using the casing running tally depths as a guide, start
20 feet above the expected collar depth and open the
knives with a low pump rate. Run down slowly, without
rotation, watching for a loss of string weight as the
knives drop into a collar recess. Repeat the procedure
to be sure.
Finding the recess between Buttress-threaded joints
should be straight-forward. Do not be surprised if it
proves impossible to locate the relatively slight recess
in a Vam casing coupling (try across a 90 foot
interval to include 2 couplings).
 Operating Procedures

11. Space out the drillstring to give maximum working

height above the rotary table at the start of the cut.
Floating rigs can be (de)ballasted to increase the
interval between connections.
12. A marine swivel landed in the wellhead is required
in making the initial cut from floating rigs. The other
response of motion compensators when relatively low
applied weight is required restricts the use of section
mills to conditions of low heave amplitude. Repeated
spudding/weight surging of the knives onto the open
cut is likely to result in premature failure of the cutting
structure.
 Cutting & Milling Operation

1. Position the mill knives at the selected cut point and

start rotation at 50 - 80 rpm, note the free rotating
torque.
2. Increase rotary speed and apply weight gradually to
initiate a moderate milling rate (4 - 5 ft/hr).
Continue at this rate for some time to establish that the
milled cuttings and swarf are being removed from the
hole in appropriate volumes. Once satisfied that the
hole is being cleaned and that the volume of swarf can
be handled on surface, the milling rate can be further
increased.
 Cutting & Milling Operation

3. The best rotary speed and weight on mill have to be

determined for each job, experiment systematically
to find the parameters which result in smooth running
and a good rate of progress.

4. Maintain a steady weight by allowing the drawworks

to creep and feed drilling line evenly. Do not allow
the weight to drill-off each time before slacking off line.
 Cutting & Milling Operation

5. Mark the pipe at the rotary table in 1' intervals and

record milling data on a sheet for each increment.

6. Increases in pump pressure are the first indicator of

a hole cleaning problem, swarf will aggregate and
pack-off the annulus in a downhole "birds nest".
Reductions in swarf volume at the shakers suggest a
near surface accumulation or blockage.
 Cutting & Milling Operation

7. Pump pressure increases may be small (less than 50

psi) or so large that the pumps have to be slowed
or even stopped. Cease milling and work the string to
attempt to clear the birds nest. If the nest is in
the riser, a means of disturbing it is to pull back far
enough so that a stabiliser can be made up into the
string and then worked down to the wellhead. If a top
drive is used, then a stand with a stabiliser at the
bottom should be racked back to save time in picking it
up.
 Cutting & Milling Operation

8. Removal of a nest around the drillstring at the bell

nipple will require some form of grab or a barbed
rope spear to be available for running on a drillfloor
tugger.

9. Pumping a hi-vis pill after each casing coupling has

been milled is recommended. If the flowline is prone to
blockage, then it may be advisable to stop milling and
flush or rod it periodically before it blocks completely.
 Cutting & Milling Operation

10. Casing couplings will mill more slowly and may

require reduced rotary speed or greater weight. Most
non-integral couplings are not threaded to the very
end, as a result the unthreaded portion breaks free
as the mill knives approach the lower end of the
coupling.

11. If drillstring is bouncing or rough running starts to

occur, then the weight and rotary speed should be
reduced for a while before attempting to gradually
increase the parameters again.
 Cutting & Milling Operation

12. Poorly cemented casing may necessitate lower

rotary speeds with less applied weight.

13. As the knives become completely worn down, the

casing will be skimmed for a while before the tool
starts to fall down inside - watch for torque changes
and increased ROP at low weights. Pull back and
locate the true lower end of the window by running
down without rotation to sit the worn knife stubs on
the casing.
 Cutting & Milling Operation

14. Once the window is complete, or the knives worn

out, ensure that the hole is circulated clean before
POOH. The point at which changes in swarf size/form
and volume is observed at the shakers can
provide a good indication of the efficiency of hole
cleaning. Turn off the pumps and rotate the string for
a few minutes to persuade the knives to collapse into
the tool body. Take care when withdrawing the
mill and stabilisers back through the top of the window.
 Cutting & Milling Operation

15. If the window is not completed with the first mill

run, then the following precautions should be observed
on subsequent runs:
a) Break circulation above the casing window to
confirm that the knives do close again afterwards.
b) Open the knives at the top of the window and lightly
ream through the section - set torque limiter at
minimum position to maintain rotation only.
c) Cut a profile on the casing stump with the new
knives at minimal weight before resuming the
window.
 Cutting & Milling Operation

16. A subsequent run with a rock-type under-reamer

may be considered if it is vital to remove all debris from
the window or to produce a consistent open hole
diameter.