Reentry Drilling

Sidetracking

Document Type UOP Template (Word 6 PC)

Software Microsoft Word 6.0 for Windows NT

Source File Sidetracking
Other Source File

Author Ike Nitis

Author info Barry W. Cross
Anadrill International S.A.
Review & approval

Revision History 04 Apr 95 Original Word 5 Mac template created.

12 Mar 96 Word 6 PC (NT) template created
11 Nov 96 Data
23 Jan 97

Confidential Reentry Drilling

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Confidential Reentry Drilling

 Table of Contents

1 Sidetracking 1-1
1.1 INTRODUCTION ............................................................................................................ 1-1
1.2 HYDRAULIC INTERNAL CUTTERS .................................................................................. 1-2
1.3 TUNGSTEN CARBIDE FOR MILLING................................................................................. 1-4
1.4 CUTTING AND RETRIEVING CASING............................................................................... 1-6
1.5 PILOT MILLING............................................................................................................. 1-8
1.6 SECTION MILLING......................................................................................................... 1-9
1.6.1 Planning a section.............................................................................................. 1-11
1.7 WINDOW MILLING ..................................................................................................... 1-12
1.7.1 System Components and BHA’s ....................................................................... 1-12
1.7.1.1 Whip ....................................................................................................... 1-12
1.7.1.2 Anchor .................................................................................................... 1-12
1.7.1.3 Mills ........................................................................................................ 1-12
1.7.2 General running procedures............................................................................... 1-15
1.7.3 Systems overview ............................................................................................. 1-17
1.7.3.1 Baker Oil Tools ....................................................................................... 1-17
1.7.3.2 Smith Drilling & Completions.................................................................... 1-21
1.7.3.3 Weatherford-Enterra................................................................................ 1-23
1.7.4 Comparison by manufacturer............................................................................. 1-24
1.7.5 Planning............................................................................................................ 1-26
1.8 SIDETRACKING WITH COIL TUBING ............................................................................. 1-29
1.8.1 Sidetrack window off cement ............................................................................ 1-29
1.8.2 Whipstocking with CT....................................................................................... 1-31
1.9 SIDETRACK PLANNING ............................................................................................... 1-33
1.9.1 System selection................................................................................................ 1-33
1.9.2 Kick off point and orientation............................................................................ 1-34

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List of Figures Page

Figure 1-1 Sidetracking options...................................................................................... 1-1
Figure 1-2 X-section view of internal hydraulic cutter operation........................................ 1-3
Figure 1-3 Mill dressing examples................................................................................... 1-5
Figure 1-4 Mill cutting action........................................................................................... 1-5
Figure 1-5 Retrieving cut casing...................................................................................... 1-6
Figure 1-6 Bowen Itco retrieving and releasing spear ...................................................... 1-7
Figure 1-7 Pilot mill........................................................................................................ 1-8
Figure 1-8 Pilot milling BHA........................................................................................... 1-9
Figure 1-9 Section mill ................................................................................................. 1-10
Figure 1-10 Planning a sidetrack through a section........................................................ 1-11
Figure 1-11 Starter mill ................................................................................................ 1-12
Figure 1-12 Starter mill BHA ....................................................................................... 1-13
Figure 1-13 Window mill.............................................................................................. 1-13
Figure 1-14 Watermelon mill........................................................................................ 1-13
Figure 1-15 String mill.................................................................................................. 1-14
Figure1-16 Flexible window milling BHA...................................................................... 1-14
Figure 1-17 Stiff window milling BHA .......................................................................... 1-14
Figure 1-18 Taper mill.................................................................................................. 1-14
Figure1-19 Gauge mill BHA......................................................................................... 1-14
Figure1-20 Taper mill BHA.......................................................................................... 1-15
Figure 1-21 Run No. 1................................................................................................. 1-15
Figure 1-22 Run No.2 & 3........................................................................................... 1-16
Figure 1-23 Retrieving whipstock..................................................................................... 1-17
Figure 1-24 Baker permanent packer and anchor ......................................................... 1-18
Figure 1-25 Baker bottom trip anchor ........................................................................... 1-19
Figure 1-26 Baker whipstock retrieving tools.................................................................. 1-20
Figure 1-27 Baker one trip WINDOWMASTERTM ..................................................... 1-21
Figure 1-28 Smith Tri-Mill............................................................................................ 1-22
Figure 1-29 Smith one trip TRACKMASTERTM .......................................................... 1-23
Figure 1-30 Weatherford WhipbackTM Whipstock ....................................................... 1-23
Figure 1-31 Weatherford/Enterra whipstock retrieving tools.......................................... 1-24
Figure 1-32 Planning a sidetrack through a window...................................................... 1-26
Figure 1-33 Whipstock high side orientation................................................................. 1-27
Figure 1-34 CTD cement window milling procedure ..................................................... 1-29
Figure 1-35 CTD cement window milling BHA,s .......................................................... 1-30
Figure 1-36 Custom Speed Mill ................................................................................... 1-31

List of Tables Page

Table 1-1 Comparison by manufacturer........................................................................ 1-25

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Table 1-2 Window milling considerations...................................................................... 1-27

Table 1-3 Sidetrack selection....................................................................................... 1-33
Table 1-4 Motor orientation option............................................................................... 1-34

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1 Sidetracking

1.1 Introduction
Before kicking off any re-entry or multilateral well, the original or mother bore requires to be
sidetracked. The techniques available to sidetrack are essentially the same whether the new well
be of a long, medium or short radius curvature. Depending on the existing well status and the
objectives several sidetracking scenarios are usually available. These can range from:
a) Kicking off in open hole with, or without a cement plug.
b) Removing casing to allow an open hole sidetrack.
c) Cutting or milling the casing to access the open hole.

Target A Options:

-Pilot Mill Liner Hanger & Liner to below the Larger Casing Shoe
and drill a medium radius large size hole.

-Section Mill or Whipstock below the shoe for a short radius curve.

Target

Target B Options:

-Section Mill or Whipstock the Liner to drill a medium radius curve.

-Kick off below the shoe for a short radius curve.

Target

Figure 1-1 Sidetracking options

This section will discuss techniques where some form of casing milling/cutting will need to be
performed before a sidetrack can take place. The descriptions are a general overview and it is
recommended that detailed information and operating procedures for each technique are
sourced from the supplier to assist in making recommendations to the client.

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1.2 Hydraulic internal cutters

Two techniques in the following section deal with hydraulically activated tools, either for
internally cutting casing before retrieval, or for internally cutting and then milling casing as in
section milling.
Fig 1-2 shows a four step sequence of operation for these tools:
1. Shows the tool run inside the casing to cut out depth, the string is being slowly rotated and
circulation is started (Blue arrow). The pressure drop through the piston pushes the piston
down forcing the cam onto the back of the cutters which are then forced out into the
casing(Red arrows) Note the key components:
• Piston and cam with return spring.
• Cutters are hinged and in the retracted position.
• A device (Smith call theirs a “Flo-Tel”) which restricts the mud flow prior to the casing cut
out.
2. Rotation and circulation is maintained until the cut out is completed. At this stage there may
be erratic then a reduction in rotary torque and a standpipe pressure drop detected on
surface. (The cutters are fully out, the piston is fully down and the Flo-Tel stinger is out of
the piston ID.)
3. After continuing rotation and circulation to clean the area of cuttings, the pump is turned off
and the return spring should force the piston up to the neutral position allowing the cutters to
retract.
4. Rotation is stopped and the string is slowly picked up. The cutters should retract into the
tool freely and allow the BHA to come to surface or, alternatively make another cut at
another depth.

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1. Flo-Tel 2.

Piston head with

pressure seals

Piston return
spring
Piston cam

Tool body

Cutters

3. 4.

Figure 1-2 X-section view of internal hydraulic cutter operation

For more information on cutting tools see: Baker (Tri-State), Houston Engineers (HE),
Smith (AZ), Weatherford Enterra (A-1, Homco).

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1.3 Tungsten carbide for milling

Most bladed or junk milling tools incorporate tungsten carbide material in their cutting
structures. The TC itself is blended with other materials to achieve the desired qualities for the
application. The qualities may include hardness, resistance to shocks and abrasion, ability to cut
special materials such as Inconel, etc,. The objective is to balance the qualities of long down
hole life and performance. The TC in some shape and form is then applied on the cutting tool.
Fig 1-3 indicates some common designs.

A. Is the most common design where particles of angular, crushed and sized TC are imbedded
in a matrix (usually nickel bronze) and gas welded onto the surface of the cutting tool. This
design has been the standard for all milling tools and still used today particularly for flat
bottom junk mills, washover shoes, packer milling tools and certain areas of casing milling
tools. The nickel bronze matrix acts as a shock absorber in junk milling operations and as
the individual TC particles wear or break off, more are exposed as the matrix wears away.
Incorrectly applied, this dressing may result in slow ROP (too much matrix or bad alignment
of TC) and rapid wear. The advantage of this type of dressing is that it can be applied on
practically any surface but because the TC particles are not uniformly positioned the
resulting milling performance is mixed. Milled cuttings can vary in size from hairlike stringers
several feet long to 1/4” thick or pieces several inches in length. These cuttings are difficult
to transport out of the hole and can “birdnest” above the mill. The danger of sticking the
BHA can only be avoided by frequent stops for hole cleaning and sometimes pulling out of
the hole for a separate clean out trip. Because of this and inferior down hole life in a clean
environment, this type of dressing is now rarely used in performance casing milling
operations.
B. The Smith “Mill Master” design uses stepped TC blocks approximately 2” X 1” X 3/8”
welded onto the pre-slotted base steel of their cutting blade. The net result is a solid mass of
TC cutting the material which is angled to cut much like a PDC cutter. In well cemented
casing free of loose junk, this design leads to long milling runs with consistently high ROP.
The striations, or steps are a “chip breaker” feature which break the cut material into
manageable lengths for easy transportation by the mud system.
C. Among others, Baker (Tri-State) use rounded inserts either flat or scalloped, welded onto a
flat surface for their “Metal Muncher” design. The inserts are from 3/8” - 5/8” in diameter
and thickness. The blade itself usually has a negative rake of 3-7° to the casing. It is clear
that unlike the Smith design, there will always be a gap between the round inserts and
therefore a “dead” milling surface.
D. Weatherford Enterra are among those who favor triangular and square inserts.

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A B C D

Figure 1-3 Mill dressing examples

Fig 1-4 simulates the cutting action of a cutter dressed with a TC insert set at a negative rake to
the casing, much like a PDC cutter on a drill bit. Weight and rotation is applied and the insert
bites into the steel gouging out a short “cutting” which curls over and breaks away from the
parent material.

Direction of rotation

Cutter set at negative rake

Casing

Figure 1-4 Mill cutting action

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1.4 Cutting and retrieving casing

Retrieving the casing enables drilling a larger hole sized well. If the casing is free down to the
planned kick off point, then it can be cut by hydraulic or mechanical cutters and then retrieved
with a spear. This can be done in one section or, depending on the depth, hookloads and
anticipated problems, can be cut in smaller sections before retrieving. CBL data is commonly
used to evaluate the feasibility of using this technique and it is often assumed casing will be free
down to the depth where there’s no cement. (or not a good bond) In many cases however, the
casing will be stuck even where there’s no cement behind it. Sometimes the casing will not come
freely after making a cut and there is uncertainty on the quality of the cut. A wireline “free point
indicator” is the only reliable way to identify the cutting and retrieving candidate. Fig. 1-5 shows
a fishing BHA (retrieving/releasing spear is the internal catch tool) latched on to the cut section
of casing and pulling out of the hole. The spear can be released if the casing will not pull or jar
free. Fig. 1-6 has a closer look at the Bowen Itco retrieving/releasing spear. Several strings of
casing can be cut by using a multistring cutter and pulled together.
Drill collars

Fishing jars

Fishing BHA Bumper sub

coming out of
the hole with
casing spear Stop sub
engaged onto
the top of cut Releasing spear
casing.
Outer
casing shoe

Casing cut
internally
above stuck
point.

Figure 1-5 Retrieving cut casing

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Stop sub to locate the

top of fish. Also allows
the jars to be recocked.

Spear engaging fish

with grapple in the
Bowen Itco Releasing catch position
Spear.

Top sub and mandrel

Replaceable grapple
catches a range of ID's
is mounted on the left
hand helix mandrel
operating much like a
Bowen Series 150
overshot

Lock ring

Bottom nut

Pack-off (optional)
enables circulation
through the fish.

Figure 1-6 Bowen Itco retrieving and releasing spear

For more information on internal catch tools see: Baker (Tri-State), Bowen, Houston
Engineers (HE).

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For more information on milling tools see: Baker, Smith, Weatherford Enterra.

1.5 Pilot milling

The Pilot Mill is a bladed mill (3 or more blades depending on size and manufacturer) with a
pilot guide to stabilize the milling action. There are generally no hydraulics restrictions for hole
cleaning and impressive milling rates can be achieved depending on the condition of the casing
or the cement/casing around it. Milling rates can reach up to 20ft/hour or more but are usually
controlled to allow adequate hole cleaning. Liner hangers and packers can also be milled with
these tools.(See Figs. 1-7, 1-8)
Blade OD slightly more Tungsten Carbide dressed blades and pilot
than casing collar OD

Pilot - Same OD as casing Drift ID

Figure 1-7 Pilot mill

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Slick BHA

(Jars optional and placed

high in the drill collars)

Casing Shoe

Liner cemented or stuck

inside the casing

Figure 1-8 Pilot milling BHA

1.6 Section milling

A section mill is a combination internal cutter and pilot mill. While the same principles apply as in
pilot milling, section milling differs in that the tool has to first make a cut out in the casing before
milling can begin. The tool is run inside the casing to the top of the planned section. Rotation and
then circulation is started just as when using any internal hydraulic cutting tool. Problems are
sometimes experienced when cutting out in high weight and grade casing, particularly in harsh
well conditions. (e.g. deep well, heavy mud, hot hole) After cutting out weight is applied and the
section is milled.
As in all milling operations, hole cleaning is of primary importance. Good mud properties,
controlled milling, circulation and jet subs are some of the solutions to ensure cuttings are being
carried to surface and not “bird nesting” around the tool.

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Stabilizer/Taper Mill
Jet Nozzles

Tungsten Carbide Blades open with hydraulic pressure

Figure 1-9 Section mill

See Appendix - “Procedure for Cased Hole Sidetrack - Section Milling and Underreaming”
for Smith’s generic operating procedure.

For more information on milling tools see: Baker, Smith, Weatherford Enterra.

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1.6.1 Planning a section

A
Milling Side-tracking

E
C

Code Description Comment

A Casing Collar Or casing joint.
B Casing length Start cut well below casing collar. In uncemented strings particularly, there is a
danger of backing off the stub below the collar when making the cut out with the
section mill.
C Outside Casing Casing should be cemented before milling is attempted. Loose casing, collars,
centralizers, scratchers may pose a problem when milling.
D Section Length 20ft is the minimum for a perfect short radius kick off. Additional length is
recommended for difficult formations, or if open hole is required for magnetic
orientation.
E MD from top A minimum of 5ft should be allowed.
stub to KOP
F Cement Plug Plug should be as hard or harder than the formation for a successful XF motor
sidetrack. If a hard cement sheath is likely to be left after milling, recommend to run
an under-reamer before setting the kick off plug. If cement is soft a fixed bend (non-
articulated) PowerPak may be used to initiate the kick off.

Figure 1-10 Planning a sidetrack through a section

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1.7 Window milling

Pilot or section mills remove the complete circumference of casing and then require a (usually)
cement plug to assist a sidetrack with a motor assembly. Whipstocking is a technique where a
whip or wedge, is used to deflect milling tools into the wall of the casing. As weight and rotation
is applied, a slot (or window) is cut into the casing as the mill travels down the face of the whip.
Eventually, the mills will cut through the casing and into the formation. While a directional drilling
BHA will normally follow, the sidetrack is essentially achieved with the mills.

1.7.1 System Components and BHA’s

The generic system consists of:

1.7.1.1 Whip
The “spoon”, “wedge”, or “whip” is the means whereby mills are deviated into the casing to
mill the window. The whipstock also guides the BHA’s and completions into the sidetracked
hole.

1.7.1.2 Anchor
The Anchor - Locks the whipstock in place. Once the anchor is oriented and set, it should
not move during the milling and drilling operations. Anchor systems are of two basic types:
1. Hydraulic set. - Either permanent or retrievable.
2. Bottom trip. - Can be retrieved.

1.7.1.3 Mills
Generic descriptions are:
1. The Starter Mill
Is used to convey the whipstock assembly and also makes the initial cut out in the casing. The
whipstock assembly is run to the setting depth, oriented and the anchor is set. The pin linking the
starter mill to the whip is sheared and the initial milling is started.

Figure 1-11 Starter mill

MWD/collar for survey instrument Starter mill Pinned to Whipstock

UBHO Hydraulic oil reservoir

(Gyro/steering tool/Slim) (hydraulic set anchors)

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Figure 1-12 Starter mill BHA

2. The Window Mill

Does the bulk of the milling and is run in conjunction with Watermelon and/or String Mills which
open up and smooth the window.

Figure 1-13 Window mill

Fig. 1-13 shows a window mill as a bladed junk mill slightly rounded on bottom, usually dressed
with TC inserts and chips and designed to cut ahead and to the side. Often it is not ground
smooth on the gauge OD to assist in sidecutting. Some designs have a raised point at the bottom
center, to encourage the mill to “jump over” the casing wall (half-way through the casing wall)
and avoid high centering the mill. In operation, this is seen as a reduction in milling torque while
ROP stops. Unless the mill is encouraged to exit by applying extra WOB, there is a danger of
“ringing out” the mill or even to start milling into the whip itself.

3. Watermelon mill
Fig. 1-14 shows a bladed string mill tapered on top and bottom. Normally run above the
Window mill, it opens up and smoothes the cut made by the window mill.

Figure 1-14 Watermelon mill

4. String mill
Fig. 1-15 shows the String mill as slightly longer than the Watermelon in blade length and with
less taper. It is run to stiffen the milling BHA and ensure the window is smoothed out to allow
safe passage for subsequent BHA’s.

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Figure 1-15 String mill

Drill pipe/HWDP Watermelon mill Window mill

Figure1-16 Flexible window milling BHA

Fig. 1-16 shows the first BHA run after the Starter mill is often quite limber to assist in coming
off the whip and cutting through the casing. In the 3 trip, or conventional technique, this would
be followed up by a stiffer BHA (Fig.1-17) to elongate and ream the window.

Drill collar String mill Watermelon mill Window mill

Figure 1-17 Stiff window milling BHA

5. Taper Mills
Are often run with a casing scraper as a gauge run prior to setting the whip. It is otherwise used
to open up casing or clean up tight areas inside the casing or in the window.

Figure 1-18 Taper mill

Drill collar Casing scraper Taper mill

Figure1-19 Gauge mill BHA

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Drill collar String mill Taper mill

Figure1-20 Taper mill BHA

1.7.2 General running procedures

A “standard” operation requires three trips to complete a window ready for drilling.
Fig. 1-21 simulates the first run for a hydraulically set anchor system.
A. The anchor with whip is run to setting depth pinned to the starter mill. A joint of HWDP is
run immediately above the mill for flexibility. The whip face (tool face) is then oriented with a
surveying instrument.
B. After orientation the anchor is energized and the slips are set. The whole BHA is now
locked.
C. After the anchor is set, a predetermined amount of overpull is applied and the pin and block
which holds the starter mill to the whip is sheared. The milling BHA is now freed from the
whip.
D. The starter mill is now utilized to mill away the pinning system remaining on the whip and at
the same time make an initial cut into the casing.

A B C D

Figure 1-21 Run No. 1

Fig.1-22 shows the two subsequent milling runs:

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A) The window coupled with a watermelon mill is run on a joint of HWDP to mill the window
and make the first pass into the formation.
B) The last run is with a stiff assembly of 2-3 mills made up to a drill collar. This run is to
ensure the window is smoothed out and ready for drilling.

A B

Figure 1-22 Run No.2 & 3

Some manufacturers have developed systems which can run the whipstock and anchor and
complete the window in two and even one trip. These will be described later.
In multilateral drilling through casing the whipstock is commonly retrieved after milling the
window and drilling the branch. Fig.1-23 shows that a catch tool is run on a fishing BHA to
latch onto the top of the whip and retrieve the whip and anchor allowing access to the zones
below.
A) In this example the Smith system uses a Die Collar to latch the whip. This is rotated over the
top of the whip until the internal threads begin to bite. Torque is then applied to ensure a
positive hold onto the whip.
B) Once the whip is securely latched, overpull is applied until the slip mechanism at the anchor
is disengaged.
C) With overpull, the slips are retracted and the assembly is free to be pulled out of the hole.

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A B C

Figure 1-23 Retrieving whipstock

1.7.3 Systems overview

The following section evaluates the equipment of the three primary suppliers (Baker, Smith and
Weatherford) in order to assist in well planning. In all cases, cast a critical eye on any claims
made by the suppliers on their success stories in other areas, new techniques etc,. Two major
influences to the technique are the experience of the personnel, and the standard of the
maintenance procedures, particularly redressing of the mills in the area of your operation.
Our concerns are:
• Capabilities of each system.
• How the system is deployed.
• Recommended running procedures, contingencies and estimated time.
• Result - Length and size of window and rat hole.
• Cost of the service to us and the client.

1.7.3.1 Baker Oil Tools

With their strong completion background, BOT have a range of packer based anchoring
systems as well as a bottom trip non-sealing anchor for retrievable applications.
One system is to first run and set a permanent packer - usually DW1 packer, with an orientation
key in the bore. The orientation of this key can be established with MWD if the packer is run on
drill pipe. Alternatively, if the packer is set by wireline, the packer is surveyed with a gyro or
magnetic survey tool. After the orientation of the key is established, the stinger/anchor
connected to the whip is then adjusted to the desired whip alignment at surface. This is then
conveyed to the packer with the milling BHA. Once the anchor is in the packer bore,
approximately 15Klbs of weight is slacked off to set the slips. After setting is confirmed, the pin
is sheared by slacking off a predetermined weight.

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In multilateral applications the whip and anchor can be retrieved leaving the packer in place as a
device for locating future deflection tools. The bore of the packer can be opened to allow
communication below.

Stinging in to the packer with the anchor, whip

and starter mill/running tool .

Orientation adjustable at surface.

Slips to hold in packer ID

Mule shoe
Packer pre-set in casing
Orientation key in packer bore
Slips

Packer sealing element

Slips

Figure 1-24 Baker permanent packer and anchor

In addition to the system outlined above, BOT also have a retrievable bottom trip system. This
is run with the whip/milling BHA and typically set on an isolation bridge plug. See Fig.1-25
below.

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Slips activated by plunger

Plunger

Pre-set bridge plug

Figure 1-25 Baker bottom trip anchor

Baker have two unique retrieving tool options with a Die Collar as the third choice. Their first
choice is called the Hydraulic LugTM type. To quote the Baker literature, “Pump pressure will
retract the lug, and allow the tool to move down the face of the whipstock. This will allow fluid
to clean up the debris around the retrieving slot. When the pump is cut off, the lug will extend
into position to catch the retrieving slot.”
The operating recommendations are as follows:
“RIH and stop above the whipstock. Circulate at 120 gpm while lowering the retrieving tool.
Circ. out debris from around the whipstock for approx. 30 min. Cut off pumps to put the lug in
the catch position. Several attempts may have to be made to catch the whipstock.

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Rotate the string in 30° increments and pick up until overpull is achieved. (The lug is machined in
such a manner that it cannot catch on the window.) 50,000# overpull will release the MLTM
Anchor. POOH. If the whipstock becomes stuck while pulling out of the hole, take an overpull
of 2000# and circulate at 100 gpm while attempting to rotate free.
The eccentric stabilizer may have to be run in conjunction with the lug type retrieving tool in a
straight hole. It pushes the lug away from the casing wall, and keeps it positioned to catch the
slot in the whipstock face.”
Baker has developed another option, the Rolling DogTM overshot which is also a hydraulically
actuated tool using mud flow to position a sleeve in the catch position. their operating
recommendations are: “ Make up the Rolling DogTM overshot on the drill string and RIH. Stop
above the whipstock and establish parameters while circ. @ 120gpm+. Rotate slowly while
pumping. Lower the tool over the whipstock. If it is not oriented right, it will take weight after
1/2”. Continued rotation will move it to the right position for catching. Continue lowering it for
1/2-1”. It should take weight. The tool should be picked up 1/2-1” before stopping the pumps.
Allow the pressure to equalize, then pick up. Overpull should be seen immediately. Pull up to
50,000# to release the MLTM Anchor. POOH.”
Their final method - a box tap (die collar) is described thus: “As a last choice, a box tap can be
used. It should be run with a safety joint. If excess torque is applied to the whipstock, it may
twist off, leaving a fish top that cannot be easily engaged.”
It is apparent that Baker have a priority for releasable catch devices and are fearful of the box
tap/die collar solution commonly used by other manufacturers.

Hydraulic Lug Type TM Rolling Dog TM overshot

Figure 1-26 Baker whipstock retrieving tools

Whips
Standard dimensions are: Size Length Length

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Overall (ft) Whip face (ft)

9 5/8” 19 16
7” 17 12
Milling BHA’s
In addition to the standard 2 -3 run generic system with starter mills/window & watermelon
mills, Fig.1-27 shows Baker’s WindowmasterTM one trip system. This design requires the lead
mill to be undergauge in order to be pinned to the whip. The second mill is also undergauge and
the top mill is finally full gauge. The system, although capable of saving rig time has some
drawbacks:
1. The assembly is long and requires a long rat hole before the top mill can effectively smooth
out the window to full gauge. If there is hard formation outside the casing, the lead mill can
wear out prematurely and a trip is required to change mills/BHA nullifying the “one trip” tag.
2. The long rat hole may not be desirable in some DD situations. For instance in a short radius
application.
3. The length of the flexible BHA has shown a “wandering” tendency.

Figure 1-27 Baker one trip WINDOWMASTERTM

1.7.3.2 Smith Drilling & Completions

(See Appendix for “Procedure for Cased Hole sidetrack - Whipstocking” borrowed from a
Smith hydraulic set anchor systems operations manual for their fishing engineers. Although the
outlined procedure is for a generic milling method and does not cover their one and two trip
milling, it covers aspects of the technique common to all systems.)

Smith entered the whipstocking business through their acquisition of AZ and their Pack-Stock -
a permanent packer built specifically for whipstocking. This was designed to be set hydraulically
with oil in a reservoir sub located above the starter mill. After reaching setting depth the whip is
oriented with a survey tool and then this is retrieved. A ball is dropped inside the drill pipe and
seats on a piston in the reservoir. When pump pressure is applied the oil in the reservoir is
forced out through a line connected to and running through the whip and down to the activating
mechanism in the packer/anchor. The oil pressure forces the slips out into the casing. Being
“permanent”, once the slips are set they cannot be retracted.

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 Sidetracking

Smith also have a retrievable hydraulically set Anchor-Stock with no pressure sealing elements.
Most references and diagrams seen in this chapter describe the Anchor-Stock. A high flow by-
pass system is being used for this and the Pack-Stock anchor. The design is specifically for
orientation with MWD tools where a certain level of mud flow is required for the MWD
orientation before the setting mechanism is activated (mechanism no longer requires a drop-ball
for activation) There have been some problems with these in the past (unable to pump enough
to set the anchor) usually to do with sizing or quantifying the shear pins which release the flow
diverter in the by-pass sub.
The whip is usually mounted on a hinge pin above the anchor.
In the retrievable systems, the whip is designed to shear off the anchor at a predetermined
overpull and leave a fishing neck to be latched by an overshot. The first choice for a retrieving
tool is the box tap/die collar.
To compete with Weatherford/Enterra’s lower cost systems used extensively in relatively
shallow vertical re-entry wells, the bottom trip retrievable Econostock has recently been
introduced by Smith. This is a one piece whip and body much like the W/E system.

Whips

Size Length Length

Overall (ft) Whip face (ft)
Hydraulic/Bottom Trip Hydraulic/Bottom Trip

13 3/8” 21.5/ - 17.6/ -

9 5/8” 15.4/ - 11.8/ -
8 5/8” 13.5/ - 10.3/ -
7 5/8” 12.6/ - 8.9/ -
7” 11.4/14.3 7.9/5.4
5 1/2” 8.8/11.8 6.1/6.0

Milling BHA’s
Still in use is the standard 2 -3 run generic system with starter mills/window & watermelon mills.
Smith were the first to attempt a BHA to reduce the number of milling runs to two. The whip
has to be conveyed before hand with the starter mill. Fig 1-28 shows the Tri-MillTM design, a
one piece tool which combines the window mill with two other milling profiles.

Figure 1-28 Smith Tri-Mill

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 Sidetracking

As a reply to Baker’s one trip system, the TrackmasterTM (see Fig.1-29) was developed using
the features developed for the Tri-MillTM such as the one piece BHA and the profiles of the
second and top mills. Unlike the Baker one trip, all the mills are full gauge. The tapered design
of the lead mill allows the whip to be pinned without interference to the pass through OD. The
system uses a modified whip slightly longer, with a two step profile. To date the number of runs
have been few but successful. The stated advantages over the Baker one trip system are that
milling is more efficient and a shorter rat hole is needed for a completed window.
Full gauge mills Taper mill pinned to whip Hydraulic line

Whip has a two step tapered profile.

After anchor is set and whip sheared off, the taper mill is forced aggressively into the casing over a length
of 1-2 inches. The next 2ft of milling is along a shallow angled portion of the whip followed by another steep
angle to the main whip body. The mills following the taper mill complete the milling and dress the window to
the correct gauge.

Figure 1-29 Smith one trip TRACKMASTERTM

1.7.3.3 Weatherford-Enterra
Fig.1-30 shows the Weatherford Enterra bottom trip system typically being set on a bridge plug
or cement plug. The system is relatively simple and capable of being retrieved.
Exploded internal view of Trip Mechanism
with pins sheared and in set position

Running Tool Shear Pin #2

Shear Pin #3
Slip
Plunger 4-5,000lbs
Plate to shear pins
Whip #1 & #2
Spring

Shear Pin #1
Shear Pin Sleeve
Mechanical Piston

Foot
Body 2 Upper Slips
(Stationary)
Shear Pin #2
1 Lower Slip Bridge Plug
Trip
Mechanism (Moveable)
Shear Pin #1

Figure 1-30 Weatherford Whipback TM Whipstock

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 Sidetracking

Fig.1-31 shows the two options used by W/E for retrieving the whip. The primary one is the
hook which needs to aligned so it can enter a slot on the whipface. According to W/E, the hook
design prevents it from going outside the window and inadvertently hooking onto the casing. The
hook system has been known to have problems like unable to latch the whip or coming off the
whip when overpull is applied.
Retrieving
Hook Slot Hook

Die Collar

Whip Face

Figure 1-31 Weatherford/Enterra whipstock retrieving tools

Whips
Details of dimensions are not available.

Milling BHA’s
At time of writing, W/E have a traditional approach of conveying the whipstock with a starter
mill and then using the 1-2 window/watermelon mill runs to complete the window.

1.7.4 Comparison by manufacturer

Features Baker Smith Weatherford

Systems for Permanent v v v
Anchors (Same design as
retrievable)
Seal Integrity v v v
(with a packer or (Pack-Stock) (with a packer or
separate bridge separate bridge
plug) plug)

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 Sidetracking

Systems for Retrievable v v v

Anchors Two systems: Two systems: Bottom trip.
a) Bottom Trip a) Bottom Trip
b) Whip set in b) Hydraulic set.
Packer. (Packer
is permanent.)
Seal Integrity X X X
Retrieving method 3 separate tools Box Tap a) Hook
If anchor is b) Box Tap
stuck, whip pulls
off to leave a fish
neck for
overshot.
Milling Systems a) Conventional a) Conventional Conventional
b) One Trip b) Starter/Tri-Mill
c) One Trip

Table 1-1 Comparison by manufacturer

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 Sidetracking

1.7.5 Planning
The following schematic indicates the important points to consider when planning a window
sidetrack .

B
D

Figure 1-32 Planning a sidetrack through a window

Code Description Comment
A Top of Whip Normally used as the setting depth reference point.
B Whip The length and angle of deflection is important. Long whips with smaller deflection
angles are for longer radius sidetracks. Whip face angle is in the range of 1 1/2° -
3°.
In deviated wells supplier’s recommendations on setting orientation must be known
but generally:
Milling is better achieved when the whip face is oriented no more than 60° L or R of
high side.
Hinged whips should not be set more than 60-70° from high side to avoid the
possibility of the top of the whip moving into the center and catching subsequent
BHA’s.

Fig.1-31 below visualizes the scenario of a whipstock set at high side of an inclined
well and the possibility of bad hole conditions outside the casing (soft or no cement
on the high side) for an articulated motor kick-off.

Consider how to retrieve the whip if the tool face is set to low side.

When running an XF motor, initial TF setting should be no more than 45° L/R of
high side to avoid the risk of an excessive drop in inclination.

C Anchor Some are permanent, some retrievable, have packers etc. Need to investigate the
features of the various options to select the system for the application.

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 Sidetracking

D Milling BHA For larger hole sizes and long radius applications where the BHA’s may be stiff, a
long well reamed window is desirable. For short to medium radius applications, the
length of the window and the rat hole is of particular concern. In recent times, all of
the three objectives can be achieved with two and now a single BHA. This is
potentially attractive in terms of rig time savings. The single BHA or, “one trip”
system also needs to be evaluated in terms of window and rat hole length as these
effect the directional part of the operation. As in the schematic, the distance
between the lead and the top mill in the final BHA gives an indication on how much
length there will be from the top of the window to the end of the rat hole.

E Window Casing is opened and formation is exposed above the top of the whip. The length
opened depends on the length and stiffness of the milling BHA used. Distance from
the top of the whip to where the casing is opened (top of window) and is a function
of the length. After a good milling job, the bottom of the window is no deeper than
the bottom of the whip. The whip face is 6-12ft in length depending on manufacturer
and casing size. Confer with supplier.

F Rat Hole The milling BHA continues through the opened window so that the string or
watermelon mills can smooth out the cut. The resulting rat hole can be as short as
1ft long for medium or short radius applications and as long as 30ft for long radius.
If following up with articulated motors for a short radius kick off, the rat hole should
reach good formation. An alternative would be to initiate the kick off with a fixed
bend (non-articulated) PowerPak.
For well planning purposes, add the whip face angle, considering the orientation, to
the initial well’s inclination and direction to estimate the inclination and azimuth
values at the kick off point.

G Collar Manufacturers recommend that the slips should not be set at a collar or joint.
Normally, avoid setting the whip face across a collar. In short radius applications,
where the location of the kick off point is critical, these options may not be
available.

Table 1-2 Window milling considerations

X B

A
X
Key:
B A = Rat Hole
B = Cement in washed out hole
C C = Casing set on low side of washed out hole
X = Distance to100% formation

Figure 1-33 Whipstock high side orientation

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 Sidetracking

1.8 Sidetracking with coil tubing

Coil requires the use of a down hole motor for milling, and a down hole orienting device for
indexing the tool face of the motor or deflection device.

1.8.1 Sidetrack window off cement

The technique developed by Arco and DS in Alaska uses a “time drill” approach much like the
method one would use for a deep sidetrack into hard formation with a downhole motor and a
diamond sidetracking bit. Some techniques used include:
• Special cement plug reinforced with polymer fibers.
• Diamond Speed Mills with special profiles.

A B C D

20ft minimum
Cement

Time mill
window and
sidetrack
15ft +/-

Figure 1-34 CTD cement window milling procedure

Fig 1-34 above shows the four basic steps in the technique done through any size casing and in
many cases through 4 1/2” tubing. The hole size is typically 3 7/8” OD.
A. Special cement plug set with coil.
B. CTD BHA of bit, 2 7/8”-3 1/8” steerable motor is run and oriented to one side of the
casing either with a drilling type gyro or VIPER (wireline through the coil), or with MWD
and hydraulic orienter. Approximately 20ft of hole is drilled into the cement and against the
casing wall.
C. The tool face is flipped and a ramp built to the opposite side of the casing. This will increase
the angle of approach for the milling BHA. Rough drilling should indicate when the casing is
encountered.

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 Sidetracking

D. Run in with the double bend motor and the diamond Speed Mill, enter the pilot hole and
then orient the motor up the ramp. Milling procedure initially uses time drill and hesitation
sequence as follows:
1) Start 1ft above the end of the ramp (mark the coil) and take 1 1/2 hours to mill 18 inches.
2) Take a further 1 hour for the next 6 inches.
3) Hold this position for 45 minutes, flagging this spot as “Top of Window”.
4) Take a further 1 hour for the next 6 inches.
5) Take 1/2 an hour for the next 6 inches.
6) Pick up to 12 inches (1ft) above the “Top of Window” and repeat the sequence 1-5 above.
7) Take 1 1/2 hours to make an additional 18 inches.
8) Mill the next 12-18 inches while attempting to set up to 3,000lbs of WOB to verify that a
ledge has been built on the casing. - Take care not to set too much weight.
9) Mill ahead and should expect to exit the casing from 2-9ft from the “Top of Window”.
The technique can concievably be used to drill multilaterals starting from the top branch and
working down. After drilling the top branch it should be possible to sidetrack the base of the
cement ramp, drill a straight section then build another ramp for the second sidetrack and so on.
Fig. 1-35 indicates the two BHA’s used for the technique.

Ramp drilling BHA Milling BHA

Ramp was drilled with a 1.15° bend Milling done with a double bend 278M
278M 7:8 Lobe PowerPak with no 7:8 Lobe PowerPak with no
articulation above & VIPER. articulation above & VIPER.

1.0° Bend

1.15° Bend
3.0° Bend

Rock Bit or Speed Mill Custom Speed Mill

Figure 1-35 CTD cement window milling BHA,s

Fig. 1-36 shows the specially designed diamond Speed Mill. The milling face is concave so that
once the mill cuts a step into the casing wall, it should not fall off. At the center of the concave is
a raised dimple design much like a conventional window mill, to encourage the mill to cross over
to the outside of the casing instead of staying “high centered”. The gauge length is short to
encourage side cutting action, while above the gauge cutting profile there is series of protective
diamond or TC blocks to protect the body of the mill from wear when up against the casing.

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 Sidetracking

Concave milling face with

raised central point

Hardfacing for body

protection

Short Gauge
Profile

Figure 1-36 Custom Speed Mill

1.8.2 Whipstocking with CT

The other technique for sidetracking out of casing with coil is to use a whipstock. Where well
conditions permit, a standard whipstock can either be oriented with Viper, or run below an
MWD tool and oriented with a hydraulic indexing tool. Milling is done with a mud motor. For
through tubing applications, whipstocks have the ability to expand once through the tubing and
set in the casing below. Field tests have been made with retrievable versions of these tools. Fig
1-37 is a cartoon of an expanding through tubing whipstock.
See Appendix “END OF PROJECT RECAP-COILED TUBING DRILLING” which
summarizes the recent Oman CTD campaign where standard whipstocks where adapted for
CT. There is an outline on procedures and problems.

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 Sidetracking

Running Tool on Coil

7" Casing

4 1/2" Tubing

Slips

Whip Face

Hinge Slips

Slips

A B

Figure 1-37 Through tubing whipstock

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 Sidetracking

1.9 Sidetrack planning

1.9.1 System selection
In the following table a “v” alongside the given scenario indicates which technique is the
preferred choice.

C P S W

Requirement or Status Comment

No gyro available, deviated well > 5° Direction of well’s inclination
must be known.
No gyro available, vertical well v v v +/- 40ft of open hole required
above KOP for magnetic
orientation.
Save hole size v v Casing is removed from surface
to kick off.
Casing cemented or stuck above KOP. v v
Very hard formation v Whip assists in cutting into
formation
Good cement plug not guaranteed v As above
Sidetrack through two casing strings v v v For cut & pull both strings have
to be free.
Multilateral v Access possible after retrieving
whipstock.
Substandard mud system likely v v Amount of cuttings is minimal
Corroded casing or problems behind casing v Sidetracking could still be a
problem.
Deep sidetrack v Infers long trip times, stuck
casing, hard formation, hot hole.
Hard or heavy wall casing v Amount of milling is minimal.
Casing stuck above but uncemented at kick off v Recommend cement squeeze
area before section milling.
Sidetracking could still be a
problem with XF motor.
C = Cut & Pull, P = Pilot Milling, S = Section Milling, W = Whipstock
Table 1-3 Sidetrack selection

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 Sidetracking

1.9.2 Kick off point and orientation

When selecting a sidetrack technique, several factors are taken into account before a kick off
point is identified and the build radius curve calculated. In the following scenarios,
considerations for sidetracking in open hole, after cut & pull and pilot milling are the same as for
sidetracking after milling a section.
Magnetic interference from the casing means the MWD cannot give a reliable heading for the
kick off and depending on the application, has to be backed up by a gyro tool. The gyro may
need to be regularly run to check the curve survey data until the MWD is free of interference. In
the drilling BHA the gyro seats in a UBHO above the flex non-mag which houses the MWD.
In the following table the “v” indicates where a gyro is necessary for orientation:

Source Well Scenario G Comment

Vertical or Open hole kick off. 40ft of open hole above KOP

direction Open hole kick off. MWD in or near top casing stub or
v
unknown. shoe at KOP.
Casing cut & pulled, or milled by 40ft of open hole above KOP
pilot or section mill.
Casing cut & pulled, or milled by MWD in or near top casing stub or
v
pilot or section mill. shoe at KOP.
Window Gyro needed for whipstock orientation
v as well as drilling
Deviated at Casing cut & pulled, or milled by If a turn is initiated and MWD is close
v
the KOP by pilot or section mill. to top casing stub at kick off or close
>3° in a to bottom stub while drilling the curve.
known
direction.
Window If a turn is initiated at kick off
v
G = Gyro
Table 1-4 Motor orientation option

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