i

Remedial Tools daTa handbook

Ninth Edition

P.O. Box 60068 Houston, Texas 77205-0068 U.S. and Canada: 800.US SMITH Tel: 281.443.3370 Fax: 281.233.5121 www.siismithservices.com

Requests for permission to reproduce or translate all or any part of the material published herein should be addressed to the Marketing Services Manager, Smith International, P.O. Box 60068, Houston, Texas 77205-0068.

Preface
The 9th edition of this Data Handbook contains useful, practical information on specialized downhole solutions utilizing remedial tools and services. The content focuses on areas in which we have built a combined, renowned reputation for quality service for more than 90 years. These remedial tools and services include downhole milling, sidetracking, underreaming, hole opening, pipe cutting, well abandonment and multilateral systems. The Smith Services team applies their craft daily in oil and gas fields worldwide. These experienced hands provide downhole solutions to your remedial operations. We hope this 9th edition will aid you in expediting your downhole remedial objectives. We value customer comments and will consider them for addition to our next handbook. The Field Operations, Sales, Business Development and Engineering Departments.

The following are marks of Smith International, Inc.: Anchor-Stock, Bearclaw, Drillmill, Dyna-Cut, Economill, Econo-Stock, Ezy-Change, Flo-Tel, Hevi-Wate, Hydra-Stroke, Junk Master, K-Mill, M-I SWACO, Master Drilller, Millmaster, Pack-Stock, Piranha, Reamaster, Retrievable Anchor-Stock, Retrievable Econo-Stock, Retrievable Pack-Stock, Rhino, SPX, Smith Bits, Smith Services, Trackmaster, Underream While Drilling and UWD.

Table of ConTenTs Downhole Milling

General Guidelines How to Read Cuttings Recommendations on Weights and Speeds Some Factors that Affect Milling Rates Encountering Rubber in the Hole Stabilizing the Mill What to do About Rough Operation Operating Recommendations for Milling K-Mill Flo-Tel Option Assures Positive Tool Opening General Suggestions for Effective Section Milling Recommended Procedure for Milling a Section Difficulties Encountered in Cutting Out M-I SWACO Recommendation for Mud Prep Prior to Section Milling Mud Mud Properties Flow Rate Hole Sweeps Flow Guidelines for Millmaster System Tools Total Flow Area (TFA) Fixed piston ID = .442 TFA equivalent Fluid Velocity GPM Rate Pressure Drop Mud Hole Sweeps Standard Millmaster BHA Recommendations Section Planning for Sidetracking Properties and Flow Rates Underreaming for Sidetrack Plug Using the K-Mill as a Pipe Cutter Cutting the Pipe K-Mill Disassembly Service Instructions Assembly Pilot Mills General Guidelines for Using Pilot Mills Considerations When Milling Liner Hangers and Adapters A Pilot Mill is Ideal for Washpipe Milling Drill Pipe and Drill Collars 1 2 2 2 3 3 3 3 6 6 8 8 9 10 10 10 10 11 11 11 11 11 11 11 11 12 16 16 17 17 17 17 19 19 23 23 23 23 24

Using the Pilot Mill in Swaged Completion Using a Pilot Mill Piranha Mill Offshore Slot Recovery Description of the Piranha Mill Slot Recovery Operating Parameters Mill Stability Junk Milling Junk Milling Procedures General Guidelines Loose Junk in Open Hole Stationary Junk in Open Hole Loose and Stationary Junk in Open Hole Junk Subs Taper Mills CP Taper Mill Designed for the Toughest Taper Mill Job CT Taper Mill Perfect for Milling Restrictions General Guidelines for Using a Taper Mill How to Clean Up Whipstock Windows Using a Taper Mill Procedures for Reaming Out Collapsed Casing Enlarging Restriction Through Retainers and Adapters Using a Taper Mill to Ream Out Guide Shoes Special Mills Economill Drillmill Junk Master Tungsten Carbide Products Tungsten Carbide S Tungsten Carbide Rod Application Tungsten Carbide Removal

24 24 27 28 28 28 29 30 31 31 32 32 32 35 37 37 37 38 38 38 39 39 41 41 42 43 45 45 45 47

whipsToCk operaTions
WhipStocks Retrievable Pack-Stock Operational Recommendations Retrievable Anchor-Stock Two Other Unique Advantages Anchor-Stock/Pack-Stock Running Procedure Retrievable Econo-Stock Standard Econo-Stock Running Procedure Tips for a Successful Re-entry Whipstock Sidetracking 49 49 51 51 53 53 54 54 57 57

Trackmaster Operations Trackmaster: The Only One-trip Window Milling System Trackmaster System Description High-Flow Bypass Valve Running Tool Milling Tool Lead Mill Follow Mill Dress Mill Whip Assembly Conclusions Objectives Benefits

59 59 60 60 60 60 60 60 60 60 61 62 63

ConCenTriC hole enlargeMenT

Underreaming Application of Underreamers General Guidelines for Underreaming Formation Considerations Maximum Weight on Tools with Milled Tooth/TCI Cutters Maximum Weight on Tools with PDC-Type Cutters Anticipated Life of Cutters Tool Selection Reamaster (XTU) Innovative Design Improves Underreaming Substantially Reduces Overall Casing and Cementing Costs Features Customized Cutters Improved Hydraulics Reamaster Operating Parameters Reamaster Underreaming Guidelines Cutting the Shoulder Underreaming Adding a Connection Tripping Out of the Hole Reamaster Disassembly Reamaster Assembly Drilling-Type Underreamer (DTU) Operating Guidelines Cutting the Shoulder Underreaming Adding a Connection Tripping Out of the Hole 65 65 66 66 66 66 66 67 70 71 71 71 72 72 74 77 77 77 78 78 78 81 85 85 85 85 86 86

Underreaming Key Seats 86 DTU Disassembly 87 Drilling-Type Underreamer (DTU) Assembly 89 Rock-Type Underreamer (RTU) 92 Operating Guidelines 93 Cutting the Shoulder 93 Flo-Tel Equipped Rock-Type Underreamer (RTU) 93 Underreaming the Interval 94 Adding a Connection 94 Tripping Out of the Hole 94 Rock-Type Underreamer (RTU) Disassembly 94 Rock-Type Underreamer (RTU) Assembly 95 SPX/Drag-Type Underreamer 99 Operating Instructions 100 Cutting the Shoulder 100 Flo-Tel Equipped SPX/Drag-Type Underreamer 101 Underreaming the Interval 101 Adding a Connection 101 Tripping Out of the Hole 101 SPX/Drag-Type Underreamer Disassembly 101 SPX/Drag-Type Underreamer Assembly 103 Rhino Reamer System 107 Pre-job Planning and Preparation 109 Mechanical Analysis 109 Pre-run Checklist 109 General Procedure for Making up the Rhino Reamer 110 Rhino Reamer Make-up and Surface Test Procedure for Lockout Mechanism and Hole Enlargement While Drilling Only 111 Drilling the Casing Shoe Track 112 Cutting the Shoulder 113 Hole Enlargement 113 Tripping Out of the Hole 113 Conventional, Drill and Ream, Rotary Steerable Systems 114 Operating Parameters 116

hyDrauliCs
Bit Hydraulics The Flow of Fluid Under Pressure Underreamer Hydraulics Piston Bore Velocity Hydraulic Tool Pressure Loss 117 117 118 121 121

Hydraulics Correct Orifice Selection Reamaster and Drilling-Type Underreamers (DTU) K-Mill, SPX/Drag- and Rock-Type Underreamers SPX/Drag- and Rock-Type Underreamers with Flo-Tel Determining System Hydraulics Rock-Type Underreamer, Pumping Rate 250 GPM Pressure Drops for Mud Weights Other than Ten lb/gal.

124 124 124 125 125 127 127 129

hole opening
Definition Master Driller Master Driller Tool Servicing Changing Cutters Changing Jet Orifice Changing Arm Pin Bushings Body GTA Fixed Diameter Hole Openers Features GTA Tool Servicing Nozzles Cutters and Legs Body Repair Cutter Installation Corrosion Prevention Hole Enlarger Body Types Features 0625-2600 M6980 Hole Enlarger Bodies Field Repair and Service Procedures Design and Construction Background Repairs 3600 M6980 Hole Enlarger Bodies Field Repair and Service Procedure Design Background Inspection Changing Cutter Assemblies Removal of Old Assembly Installing New Assembly Arm Replacement 135 137 138 138 138 139 139 142 143 143 143 144 146 147 147 150 150 150 152 152 152 155 155 155 156 156 156 156

well abanDonMenT
General Information 159

Shortcut 97/8 in. Cut & Pull Assembly with Seal Assembly Retrieving Tool Assembly Procedure Pipe Cutters Pipe Cutting Operating Parameters Jack-ups and Submersibles Semi-submersibles and Drill Ships Pipe Cutter Assembly for Floaters Selecting P-Cutter Lengths and Diameters Calculating Spacer Sub Lengths for P-Cutters Examples of Spacer Sub Length Sizing Selecting P-Cutter Lengths and Diameters Example of Arm Size Selection Pipe Cutter Disassembly Servicing Assembly Casing Back-off Tool Features and Benefits Applications Marine Support Swivel Marine Support Swivel Disassembly Servicing Assembly The Dual Plug and Abandonment System Only Smith has it Mechanical Cutting vs. Explosive Severing One-trip Cut and Recovery Dyna-Cut Deepwater Wellhead Severing System

159 159 159 161 161 162 162 163 163 164 164 166 166 169 169 169 172 172 172 181 174 174 174 177 177 177 180

referenCe Tables
API Casing Data Rock Bit Comparison Chart Recommended Rock Bit Make-up Torque Nozzle Types and Applications for Smith Bits Rock Bit Comparison Chart Smith Bits Drill Bit Nomenclature IADC Dull Bit Grading How to Convert Wags to Swags A. Bit Selection Equations B. Bit Weight-Rotational Speed Equations C. Hydraulic Calculation Equations D. Drilling Fluid Property Equations 181 183 184 185 186 191 192 193 194 194 195 198

Nomenclature 199 Recommended Minimum Make-up Torque (ft/lb.) 201 Rotary Shouldered Connection Interchange List 209 Top Sub Make-up Torque Table (ft/lb.) 211 Recommended Maximum-Minimum Tool Joint Dimensions (in.) 212 Drill Pipe Data 213 Internal Upset 213 External Upset 213 Hevi-Wate Drill Pipe 214 Capacity and Displacement Table Hevi-Wate Drill Pipe 214 Dimensional Data Range II 215 Tubing Data 216 Non-upset 216 External Upset 216 Drill Collar Weights (lb/ft.) 217 Weights of 30 ft. Drill Collars (lb.) 218 Buoyancy Factor and Safety Factor 219 Buoyancy Effect on the Drillstring 219 Safety Factor 219 Buoyancy Factors 220 10 in. Duplex Pump 221 12 in. Duplex Pump 222 14 in. Duplex Pump 222 15 in. Duplex Pump 223 16 in. Duplex Pump 223 18 in. Duplex Pump 224 20 in. Duplex Pump 224 7 in. Stroke, Triplex Pump 225 8 in. Stroke, Triplex Pump 225 226 81/2 in. Stroke, Triplex Pump 9 in. Stroke, Triplex Pump 226 91/4 in. Stroke, Triplex Pump 227 10 in. Stroke, Triplex Pump 227 11 in. Stroke, Triplex Pump 228 12 in. Stroke, Triplex Pump 228 Hardness Conversion Table - Approximate Values 229 Impression Diameter Hardness Table 230 Conversion Factors - Fraction to Decimal 232 Conversion Factors - English and Metric 233

inDex

237

Downhole Milling

Downhole Milling
The word milling means to cut, grind, pulverize or break down metal into smaller particles. These particles are then circulated up the annulus. The mills cut up objects that fall or get stuck in the hole or can mill away entire sections of casing. All mills are dressed with a special tungsten carbide blend, specially designed to improve milling performance. The mills are available in two basic categories: fixed blade tools and hydraulically activated mills.

General Guidelines

Annular velocity should be maintained at 80 to 120 ft/min. Oil-base mud should be avoided whenever possible. Ordinarily, no difficulty is encountered in circulating drilled cuttings under normal drilling practices. However, milled cuttings are much heavier so weighing the mud has little effect on cutting lift. A ratio of Plastic Viscosity to Yield Point (PV/YP) as ratio as close to 0.5 is ideal for steel cutting removal. If the ratio is higher than 1.0, a common remedy is to add lost circulation materials, pills or agents to the mud system. This will help to sweep the hole and will aid in carrying the steel cuttings up the annulus and out of the hole. Polymer muds are best for milling. Clay-base muds would be a second choice. Oil-base muds would be third. These choices are based on the carrying ability of the mud. Oil-base muds have poor carrying capabilities and often result in more troublesome jobs. Never mill faster than it is possible to remove cuttings. In optimum conditions, it is recommended to start with a high laminar flow. Small adjustments can be made in the flow rates, rotary speed and weight while monitoring the cuttings for size, shape and thickness. If bird nesting occurs, pull up and circulate until proper cutting return is achieved. On small workover rigs and deep drilling jobs with limited hydraulics, sweep the hole with viscous slugs every two to three hours. During long milling jobs, this procedure should be repeated frequently to maintain an optimum Rate of Penetration (ROP). Place ditch magnets in the mud system prior to milling. This will decrease pump damage from cutting contamination. The first four to five ft. of a milling job are extremely critical, especially during section milling. Cuttings tend to accumulate at the cutting knife, causing bird nesting. If this occurs, pull the kelly up five ft. and ream down slowly. Always inspect the ID of subs and other tools to ensure they are full bore. This will minimize hydraulic problems. A junk basket can aid in catching the larger cuttings. This is especially true when milling old, split or corroded casing. Junk baskets are placed in the string just above the mill.

2 How to Read Cuttings

Downhole Milling

The ideal cutting is usually 1 32 to 1 16 in. thick and one to two in. long. If cuttings are thin, long stringers, penetration rates are too low. Increase weight on the tool. If fish-scale-type cuttings are being returned when pilot or section milling, penetration rates will improve by decreasing weight and increasing RPM. This is more common when milling H-40 and K-55 casing. When milling N-80, P-110, Q-135, etc., longer cuttings will be returned.

Recommendations on Weights and Speeds

Generally the most efficient milling rates are obtained by running the rotary at 80 to 100 RPM. Milling with washover shoes is an exception; they are usually more efficient when run at 60 to 80 RPM. (As with all milling tools, speed and weight will be dictated by actual conditions.) Always start rotating about one ft. above the fish. Lower onto the fish and vary the weight to improve penetration. Whenever possible, maintain a constant milling weight. Feed the drum slowly, allowing the drawworks to creep; do not drill off. The wear pattern on section and pilot mills is a great indication of its performance. If the blades show a hook wear pattern, then the mill is working efficiently. If a tapered pattern exists, ease off on the weight applied.

Some Factors that Affect Milling Rates

The type and stability of the fish (cemented or not), the weight on the mill, the speed at which it is run and proper carbide dressing of the mill are all factors which will affect milling rates. The hardness of the fish or cement will also affect a mills performance. When milling cemented casing, penetration rates can be increased by using higher weight and speeds. Uncemented casing should be milled at lower speeds with less weight. When severely corroded casing is encountered, a high-speed, light-weight run will prevent tearing or splintering of the fish. Recommended milling rates can be found in the Normal Milling Rate table on Page 4.

Encountering Rubber in the Hole

Rubber always presents a problem during milling. When encountered, pull up and spud the mill to get a bite on the rubber. When necessary, pull the mill and clean the fish by running a drill bit.

Downhole Milling Stabilizing the Mill

A mill that moves eccentrically does a poor job. In vertical wells stabilize above the mill at 60 or 90 ft. intervals. The stabilizer OD should not exceed the dressed OD of the mill. Section and pilot mills should also be stabilized to the drift diameter of the casing, 1/2 to 1 in. under drift on taper mill.

What to do About Rough Operation

When bouncing or rough running occurs, decrease speed and weight, then slowly increase speed and weight until an acceptable ROP is obtained. If rough running reoccurs, once again decrease and then gradually increase to a maximized ROP.

Operating Recommendations for Milling

The RPMs required for good milling rates will vary. If run at high rotary speeds, the mill can hang up and stick momentarily. The string will then violently untwist, often breaking tool joints or twisting off pipe. Thus, RPM is limited by the drillstring and hole conditions. High speed can burn or damage the tungsten carbide which is critical to milling the steel. Tungsten carbide cuts steel best at 250 to 340 surface ft. per minute or 3,000 to 4,000 surface in. per minute. The following rule of thumb will help you determine the minimum/maximum recommended RPMs: Min./max. RPM = Surface speed Tool OD x 3.14

Thus, for a 8 5 8 in. milling tool: RPM min. = RPM max. = 3,000 = 111 RPM 8.625 x 3.14 4,000 = 148 RPM 8.625 x 3.14

Note: Slow rotary speed to avoid fracture damage to the carbide if mill is bouncing or torquing up.

4 General Operating Recommendations for Milling Type of Mill

Junk mill Pilot mill Taper mill / string taper mill Economill Washover shoe Section mill Drillmill Junk Master

Downhole Milling

Weight (lb.)
4,000 - 10,000 6,000 - 10,000 2,000 - 4,000 2,000 - 8,000 2,000 - 6,000 4,000 - 8,000 2,000 - 4,000 2,000 - 4,000

Remarks
Spud mill from time to time Vary weight to attain best cutting speed Start with light weight and low speed Maintain light weight and low speed Pick up from time to time Do not mill faster than cuttings are removed Start with light weight and low speed Do not mill faster than cuttings are removed

Normal Milling Rate Milling Rate (ft/hr.) Material

Casing Drill pipe Drill collars Packers Bits, cones, etc. General junk Washpipe 2-6 1-2 4 2-4 3-5 4-6 2-4

Junk Mill

Pilot Mill Piranha Economill

4-6 6-8 2-3 2-3 8 - 12

Section Mill
4-8

Rotary Shoe Washing Over

6 4 2-3

Downhole Milling Section Milling

Millmaster Assembly Showing Chip Breaker Cutting Structure Millmaster systems are only available on a rental basis in conjunction with Smith job supervision. U.S. Patent Number: Carbide Insert Milling Tool 4,710,074

Downhole Milling

K-Mill
The K-Mill is a hydraulically actuated tool used to mill a section in casing or tubing. The K-Mill is simple in design, easy to operate and has an outstanding reputation for milling performance. Milling knives are dressed with Millmaster tungsten carbide. This is effective for milling casing which is poorly cemented, split or corroded. Millmaster systems utilize patented tungsten carbide inserts to provide extended footage with maximum penetration rates. The cutting structure consists of Millmaster carbide arranged in a brick-work pattern. The carbide, being specially developed for downhole application, prevents premature wear and breakage. Upon circulation through the tool, a pressure drop is created across the piston. This forces the cam down and expands the cutter knives into contact with the casing. Cut-out knives part the casing, then all the knives participate in milling. When circulation is stopped, the piston spring will retract the piston, causing the cam to withdraw from between knives. The knives are now free to collapse back into the body and the tool can be retrieved. The tools cutting action is very effective. Typically up to 60 ft. sections are completed with one set of knives dressed with Millmaster carbide.

Flo-Tel Option Assures Positive Tool Opening

The exclusive Flo-Tel option on the K-Mill provides the positive indication that the cut-out has been made. This eliminates the possibility of skinning the inside of the pipe instead of milling it up. When the cut-out is complete, flow areas through the tool more than double. This results in a decreased stand pipe pressure between 200 to 250 psi noticeable at the surface. These are positive signs to the operator that cut-out is complete. Weight can now be set on the tool to start milling. The Flo-Tel system provides maximum cutting force against the casing during cut-out.

Downhole Milling Schematic of Staged Knife Opening

Higher pressure against casing for cut-out

Pressure drop for milling

Six cutter knives three for cut-out, six for milling

8 General Suggestions for Effective Section Milling

Downhole Milling

It is important that the mill completely cut through the casing so the blades can be firmly seated on the casing. When operating a section mill without a Flo-Tel, prolong the initial cut-out operation to ensure complete cut through.
Note: Without Flo-Tel there will not be a 200 to 250 psi indication at surface once cut-out is achieved.

If you suspect the casing to be corroded, use lower weights with increased RPM. If you experience a sudden drop off in the milling rate, the decrease may be the result of a loose ring of steel from the casing coupling. This ring will rotate with the section mill, preventing the mill from cutting properly. Try spudding the section mill gently. This should break up the ring and help position it for milling.

Recommended Procedure for Milling a Section

Run in the hole to the desired depth of cut-out. Pump rates for the K-Mill are predetermined and depend on tool size. Therefore, the correct GPM must be selected to produce the desired pressure drop through the K-Mill, assuring good tool operation. To determine the best GPM, see the following table.

Flow Rates K-Mill Series Number

3600* 4100 4500 5500 6100 7200** 8200** 9200** 11700

GPM Range Required During Cut-out During Milling

110 - 160 80 - 125 80 - 125 80 - 125 80 - 125 80 - 125 80 - 125 80 - 125 350 - 450 110 - 160 110 - 160 150 - 200 200 - 250 200 - 250 200 - 300 300 - 400 350 - 450 350 - 600

** Does not have Flo-Tel option. ** Jetted top sub is required for flow rates exceeding 300 GPM in order to minimize excessive velocity through piston which could result in erosion and/or washout.

Downhole Milling
Start rotation at 60 RPM and build pressure slowly until cut-out GPM is achieved. Keep rotating until the pipe has been severed, as indicated by the Flo-Tel (approximately 200 to 250 psi pressure drop). After the cut has been completed, increase GPM to recommended milling flow rate. Now start applying weight and increase the rotational speed to 80 to 120 RPM. The most efficient weight range is normally 4,000 to 8,000 lb. Once the section is milled, or when the knives are worn out, circulate for five to ten min. This will ensure proper closure (hydrostatic equalization). You may pull the tool into the shoe and trip out in the conventional manner.

Difficulties Encountered in Cutting Out

The most common cause of difficulties in cutting out is insufficient pressure at the tool. Approximately 300 psi is the minimum necessary to keep the cutting knives open and part the casing. Excessive pump surging in the drillstring, with subsequent yo-yoing of the pipe, may cause the blades of the mill to try to part the casing over a considerable interval. Lost circulation material, pieces of drill pipe rubbers or other substances may block the orifice of the tool, causing the mill to function improperly and delay cut-out. Watch the shaker for cuttings. Good cutting return is essential or problems can develop. Periodic hole sweeps at two- to three-hour intervals are recommended in order to aid cutting lift.

10

Downhole Milling

M-i SwACo ReCoMMenDAtion foR MuD PReP PRioR to SeCtion Milling

Mud
XC (xanthan gum)-treated polymer muds are preferred due to their high viscosity at low shear rates. These XC polymer muds have good plastic viscosity to yield point ratios (usually 0.50:1 or better). Partially Hydrolyzed Poly Acrylamide (PHPA) polymer muds are not recommended for milling due to the rapid shear degradation of the viscosity. While the plastic viscosity to yield point ratio is often specified to be between 0.75 to 0.50 to 1, more meaningful parameters to monitor are the 3-RPM Fann reading and initial gel strength. M-I recommends the 3-RPM Fann reading and gel strength to be between one to two times the hole size in inches. Clay-base systems are also acceptable if the 3-RPM value and initial gel are kept in this one to two times hole size (in.) range. Clay-base milling fluids usually require a XC polymer-type additive to achieve these levels of viscosity or must be flocculated with lime, a polymer (like PHPA or GELEX), or with a Mixed Metal Hydroxide (MMH)-type product. Oil-base muds are usually not recommended for milling because it is more difficult to obtain this level of 3-RPM and initial gel. Oil-base fluids require a rheology modifying additive and higher water contents for this purpose.

Mud Properties

Maintain in the 3-RPM Fann and initial gel strength readings between one to two times the hole size in inches. This level of low shear viscosity should give a plastic viscosity to yield point ratio between 0.50 and 0.75. This value should not be allowed to go over 0.75.

Flow Rate

A flow rate capable of producing an annular velocity between 250 and 350 ft/ min. is recommended for all milling operations. This is similar to the 35 to 50 GPM times casing ID (in.) recommendation. A bypass jet (jetted top sub) may be required for higher flow rates to reduce the risk of washout or cavitation. Remember that it is the combination of high annular velocity and high viscosity which provides hole cleaning when milling; if the viscosity needs to be increased, so does the velocity.

Downhole Milling Hole Sweeps

11

Periodic high viscosity sweeps should be used on a frequent basis depending on milling rate and cutting size to prevent shavings from accumulating in the well. Lost Circulation Materials (LCMs) are also beneficial for these sweeps due to mechanical lifting capability of fiberous materials. While fiberous LCMs like cottonseed hulls or cane fiber work best, granular LCMs like nut plugs are also effective.

flow guiDelineS foR MillMASteR SySteM toolS

Total Flow Area (TFA) Fixed piston ID = .442 TFA equivalent Fluid Velocity
Maintain internal piston velocity at 150 to 200 ft/sec. Piston cavitation in longer section milling intervals will occur at velocities over 200 ft/sec.

GPM Rate

GPM flow rates from 35 to 50 times casing ID is a good rule of thumb. However, since velocity is a function of flow rate (GPM) and TFA (fixed at .442 in.2), the flow rates must be adjusted so as not to exceed the maximum velocity stated above.

Pressure Drop

Maintain pressure drop (P) at 200 to 500 psi across piston; higher values can be used for short milling intervals only.

Mud

Polymer muds would be a first choice and clay-base muds would be second. Most oil-base muds have inferior steel cutting carrying capabilities, which can cause serious hole cleaning problems and bird nest accumulation. When lease water is used, gel additives will provide some lift for the steel cuttings. In this situation, extra rathole to fall cuttings is an option when environmentally possible.

Hole Sweeps

Periodic gel sweeps or even LCMs such as walnut hulls, etc., and working the pipe every two to three hours will minimize cutting accumulation.

12

Downhole Milling

StAnDARD MillMASteR BhA ReCoMMenDAtionS

1. Guide mill (dressed approx. 1/2 to 1 in. under drift diameter) Verify through Automated Bottom Hole Assembly Profile (ABHAP) analysis, no touching of casing ID allowed. 2. Millmaster (stabilizer sleeve dressed to casing drift diameter) Straight hole vs. angle hole diameters may vary slightly. Verify through ABHAP analysis. 3. Millmaster top sub and float sub or Millmaster top sub with box-up connection bored for float 4. Pony collar at eight to ten ft. long Make-up in shop with lifting sub to save rig time. 5. Drill collars Quantities based on size and weight of casing to be milled. 6. Stabilizer Use a milling-type stabilizer staged so it will always remain in upper casing stub. 7. HWDP Enough joints to accommodate normal transition to/from drill pipe. 8. Drill pipe

Use in holes with maximum 15 degree angles; verify through ABHAP analysis.

Downhole Milling Casing and K-Mill Correlation - API Casing Casing Specifications K-Mill Specifications Tool Wt. per Knife Casing Max. Casing ft. with ID of Casing Series Dressed Stop Coupling Collapse Size Coupling Casing Drift ID Body Open Stabilizer Dia. OD Dia. (lb.) Dia. Dia.
412 5.000 9.50 11.60 13.50 11.50 13.00 15.00 18.00 13.00 14.00 15.50 17.00 20.00 23.00 15.00 18.00 20.00 23.00 17.00 20.00 24.00 28.00 32.00 17.00 20.00 23.00 26.00 29.00 32.00 35.00 38.00 4.090 4.000 3.920 4.560 4.494 4.408 4.276 5.044 5.012 4.950 4.892 4.778 4.670 5.524 5.424 5.352 5.240 6.135 6.049 5.921 5.791 5.675 6.538 6.456 6.366 6.276 6.184 6.094 6.004 5.920 3.965 3.875 3.795 4.435 4.369 4.283 4.151 4.919 4.887 4.825 4.767 4.653 4.545 5.399 5.299 5.227 5.110 6.010 5.924 5.796 5.666 5.550 6.413 6.331 6.241 6.151 6.059 5.969 5.879 5.795 3600 358 4100 418 4500 334 334 358 414 418 418 4 434 434 458 458 412 438 514 518 5 478 578 534 558 512 538 614 618 6 6 578 534 534 558 558 558 512 6516 6316 6316 6116 7716 7716 7516 7516 7316 7116 71516 71316 71116 7916 81116 8916 8716 8516 8316 9116 81516 81316 81316 81116 8916 8916 8716 378 378 334 438 414 414 418 478 478 434 438 458 412 538 514 518 5 6 578 534 558 512 638 614 618 618 6 578 578 534

13

5.563

512

6.050

412

4500 412 5500 512 5500

6.625

658

7.390

7.656

512

Note: All dimensions are given in inches unless otherwise stated.

14

Downhole Milling Casing and K-Mill Correlation - API Casing (continued) Casing Specifications K-Mill Specifications Tool Wt. per Knife Casing Series Max. Casing ft. with ID of Casing Dressed Stop Coupling Collapse Size Coupling Casing Drift ID Open Stabilizer Dia. OD Body Dia. (lb.) Dia. Dia.
17.00 20.00 23.00 26.00 6.538 6.456 6.366 6.276 6.413 6.331 6.241 6. 15 1 6100 614 618 678 678 9116 81516 81316 81316 638 614 618 618

7.656

618

758

8.500

20.00 24.00 26.40 29.70 33.70 39.00 20.00 24.00 26.40 29.70 33.70 39.00 24.00 28.00 32.00 36.00 40.00 44.00 49.00 29.30 32.30 36.00 40.00 43.50 47.00 53.50

7. 1 25 7.025 6.969 6.875 6.765 6.625 7. 1 25 7.025 6.969 6.875 6.765 6.625 8.097 8.017 7.921 7.825 7.725 7.625 7.511 9.063 9.00 1 8.92 1 8.835 8.755 8.68 1 8.535

7.000 6.900 6.844 6.750 6.640 6.500 7.000 6.900 6.844 6.750 6.640 6.500 7.972 7.892 7.796 7.700 7.600 7.500 7.386 8.907 8.845 8.765 8.679 8.599 8.525 8.379

5500

512

678 634 658 658 612 638 678 634 658 658 612 638 734 734 758 712 738 738 714 834 858 858 812 838 838 814

91116 9916 9716 9716 9516 9316 91116 9916 9716 9716 9516 9316 1158 1158 11716 11516 11316 11316 11116 121116 12916 12916 12716 12516 12516 12316

73 678 634 634 658 612 73 678 634 634 658 612 778 778 734 758 712 712 738 878 834 834 858 812 812 838

6100

758

8.500

618

7200

858

9.625

714

7200

958

10.625

714

Note: All dimensions are given in inches unless otherwise stated.

Downhole Milling Casing and K-Mill Correlation - API Casing (continued) Casing Specifications K-Mill Specifications Tool Wt. per Knife Casing Series Max. Casing ft. with ID of Casing Dressed Stop Coupling Collapse Size Coupling Casing Drift ID Open Stabilizer Dia. OD Body Dia. (lb.) Dia. Dia.
29.30 32.30 36.00 40.00 43.50 47.00 53.50 32.75 40.50 45.50 51.00 55.50
9.063 9.001 8.921 8.835 8.755 8.681 8.535

15

958

10.625

8.907 8.845 8.765 8.679 8.599 8.525 8.379 10.036 9.894 9.794 9.694 9.604

8200

714

834 8 5 8 8 5 8 812 8 3 8 8 3 8 8 1 4 978 934 958 912 938

1258 12716 12716 12516 12316 12316 12116 1334 1358 13716 13516 13316

878 834 834 858 812 812 838 103 978 934 958 912

1034

11.750

10.192 10.050 9.950 9.850 9.760

9200

914

1134

12.750

38.00 42.00 47.00 54.00 60.00

11.150 11.084 11.000 10.880 10.772

10.994 10.928 10.844 10.724 10.616

9200

914

1034 1034 1058 1012 1038

141116 141116 14916 14716 14516

1078 1078 1034 1058 1012

1338

14.375

48.00 54.50 61.00 68.00 72.00

12.7 15 12.615 12.515 12.415 12.347

12.559 12.459 12.359 12.259 12.191

11700

1134

1238 1214 1218 1218 12

171116 17916 17916 17716 17516

1212 1238 1214 1214 1218

16

17.000

55.00 65.00 75.00 84.00

15.375 15.250 15.125 15.010

15.187 15.062 14.936 14.822

11700

1134

15 1478 1434 1458

1912 1938 1914 1918

1518 15 1478 1434

Note: All dimensions are given in inches unless otherwise stated.

16 Section Planning for Sidetracking

Downhole Milling

In preparation for milling sections, the following should be reviewed: If a formation log is available and there is a choice of where to cut your section, a section cut in a sand formation will normally result in fewer problems than one that is cut in a shale formation. First, a plug will have to be set to isolate the old well. A bond log is preferred to determine if cement is behind the casing to be milled. If you are not sure of a good cement, you should plan to block squeeze the section. Never start just below a casing collar. Plan an extra rathole (100 to 150 ft.) below the section: - This extra length may be needed during milling if cutting removal becomes a problem. - It can be used to block squeeze if needed. Polymer muds are best for milling since they have reduced PV/YP ratios and can be maintained as close to 0.5 as possible. Clay-base muds have good carrying capabilities but result in more troublesome jobs and, therefore, should be avoided when possible. Oil-base muds have poor cutting carrying capabilities and result in more troublesome jobs and, therefore, should be avoided when possible. The length of section needed will depend upon the following: Type of well plan and objective. The necessary rate of build. Type of deflection tool used.

Properties and Flow Rates

The fastest way to remove steel cuttings from the hole is with a turbulent flow. Turbulent flow, however, can also be the fastest way to get into trouble due to: Bird nesting of the cuttings. Loading of the hole creates turbulent flow due to the restriction caused by cuttings in the annulus. - This is especially critical at the beginning of the section where the drill collars are still inside the casing. Laminar flow increases slip velocity, causing particles to fall through the mud and fill up the lower stub. - Small adjustments in the flow rate, rotary speed and weight-on-tool can be made while carefully monitoring the returns from the size, shape and thickness.

Underreaming for Sidetrack Plug

Underreaming may be required (especially in small casing sizes) to allow for a large plug to be set. The cement for the plug has to be calculated to allow for correct displace-

Downhole Milling
ment of the lower stub, the open hole in the section area and at least 100 ft. of cement inside the casing above the section. This is needed to allow the operator to test the plug and dress off the top contaminated part of the plug before starting the sidetrack. The cement plug must be hard enough to perform the sidetrack. The cement in the section area must have a uniform consistency. It has to be large enough to prevent going off the side of the plug and creating a sharp dogleg. Trip in hole with a bit to dress off and test the plug after approximately 16 hours. A minimum of three ft. into the section should be drilled before picking up the mud motor and directional assembly.

17

Using the K-Mill as a Pipe Cutter

The K-Mill is very effective in cutting single strings of casing. The efficiency of the knives in conjunction with the Flo-Tel feature ensures optimum results.

Cutting the Pipe

Pick up the tool and run in hole to cutting depth. Start rotary speed at 80 to 100 RPM; note torque. Start pump slowly and increase volume and pressure until you notice a reaction at the rotary or torque (amps) increases significally. Maintain a rotary speed of 80 to 100 RPM. When cut is complete, there is a definite indication a momentary loss of returns or an increase of mud in the annulus. Quite often excessive noise will indicate when the casing is parted. The loss of torque, a decrease in pump pressure, or both, are indications the cut has been completed. Shut off pumps. Stop rotary. Pull out the hole.

K-Mill Disassembly

Remove top sub. Remove Flo-Tel assembly. (Note: Flo-Tel not available for 3600 Series.) Remove arm-stop stabilizers. Remove hinge pins. Remove the knives. Do not remove lugs. Using wrenches furnished in tool kit, remove cam locknut and cam. Piston and spring may not be withdrawn from the body. Remove piston head retaining screws. Remove orifice and anti-wash tube from piston ID.
Note: The 3600, 4100 and 4500 Series tools, due to the restricted piston diameter, do not have an anti-wash tube. Remove orifice O-ring.

18 K-Mill Components

Downhole Milling

Top sub

Cone cap Flo-Tel tensions screw

Flo-Tel assembly

Piston head O-ring Spring Orifice Anti-wash tube Piston Hinge pin retaining screw Cam Retaining screw Cam lock nut Body Arm stop body stabilizer

Piston packing Piston head retaining screw Lug Arm hinge pin

Milling knife

Downhole Milling Service Instructions

19

The tool should be thoroughly cleaned after completion of each job. Steam cleaning is best. When not available, cleaning solvents may be used. All packing should be inspected after cleaning and replaced if any wear is visible. When the tool is reassembled, all parts should be thoroughly lubricated. Any light grease is suitable.

Assembly

Replace the Flo-Tel orifice (complete with packing) into the piston after sliding the anti-wash tube into place.
Note: The 3600, 4100 and 4500 Series tools do not have antiwash tubes.

Replace the piston packing and piston head. Secure the piston head to piston with the piston head retaining screws. Make up firmly. Make sure the V-type lips of the packing are face up. Place spring over piston and slide assembly into the body. Using wrenches furnished on tool kit, make cam up firmly on the piston. Make up cam locknut firmly to prevent backing off. Assemble Flo-Tel loosely: - Place stinger in seat. - Place bail on cone cap. - Align holes in seat and cone cap and start threads of the tension screws. Do not make screws up tightly at this point, as this will expand the bail and the assembly will not enter the body. - Slide the Flo-Tel assembly into the body. The bail will snap into place when properly positioned. - Tighten tension screws firmly. This expands the bail into its mating groove in the body and locks the assembly into its proper place. Install new knives, hinge pins and hinge pin retaining screws.
Note: The spare knives are packaged complete with hinge pins and retaining screws. Do not attempt repeated use of these items.

Install and tighten arm-stop body stabilizers.

20 K-Mill
Fishing neck diameter Top pin connection Body diameter

Downhole Milling

Fishing neck length

Nominal overall length

Downhole Milling Section Mill Specifications Tool Casing Sizes Series

3600 4100 4500 5500 6100 7200 8200 9200 11700 412 5 512, 6 658, 7 758 858, 958 958 1034, 1134 1338, 16

21

Body Dia.
358 418 412 512 618 714 814 914 1112

Fishing Neck Length

18 18 18 18 18 18 18 18 18

Fishing Neck Dia.

318 314 418 434 434 534 534, 8 534, 8 8, 9

Overall Length
56 66 70 74 74 89 87 87 90

Top Pin Conn.

238 238 278 312 312 412 412, 658 412, 658 658, 758

Wt. (lb.)
135 175 220 350 368 554 900 980 1,725

Notes: 1. All dimensions are given in inches unless otherwise stated. 2. All weights are approximate. 3. Standard API regular pin connections. Others available upon request. 4. Flo-Tel is standard equipment for 4100 through 11700 Series.

Ordering Instructions: When ordering or requesting quotations on section mills, please specify: 1. Tool series 2. Size and weight of casing to be milled 3. Top pin connection

22 Pilot Mill

Downhole Milling

Downhole Milling

23

Pilot MillS
Pilot mills are recommended for milling washpipe, safety joints, crossover swages and washover shoes. Liner hangers can be milled efficiently, eliminating inside cuts and running spears. The nose, or pilot, can be dressed to mill out junk which may be encountered. Pilot mills can be used to mill: Adapters Casing Liners Washpipe Drill pipe Swaged casing In selecting a pilot mill, the blade OD should be about 1 4 in. larger than the OD of the tool joint or coupling to be milled. The pilot OD should be the same as the drift diameter of the tubular. The best speed and weight to run a pilot mill must be determined for each job. Also, conditions may change from one pilot milling job to the next in the same well. This may require different speeds and weights at different times. In the absence of experience, start with a rotary speed between 80 and 100 RPM and a tool weight of 2,000 to 6,000 lb. or less. If when milling swaged casing a sudden drop-off in milling rate occurs, the trouble may be caused by a loose ring of steel formed at a joint or weld which is turning with the pilot mill. Try spudding the pilot mill gently. This should break up the ring and help position it for milling. If cutting stops altogether when milling washpipe, casing or liner, and there is no noticeable increase in torque, there is a good chance a section of the casing or tubular is turning. If this is the case, pull the mill and attempt retrieval using a spear.

General Guidelines for Using Pilot Mills

Considerations When Milling Liner Hangers and Adapters

On most liner milling jobs, a pilot mill is used to first mill the liner hanger or adapter, and then the liner. In some cases the liner hanger or adapter is milled using a junk mill. Then the liner is milled with a pilot mill. This latter method is preferred if there is hard cement behind the liner or if the liner has numerous bow-springs, slips, etc.

A Pilot Mill is Ideal for Washpipe

The pilot mill is the most efficient tool for milling stuck washpipe. If drill pipe or collars are inside washpipe, however, they must first be milled with a junk or smaller pilot mill.

24 Milling Drill Pipe and Drill Collars

Downhole Milling

If the ID is open, drill pipe and collars are sometimes milled with pilot mills. If the drill pipe or collar is cemented inside the casing, particularly in deviated holes, the pipe is probably lying on the low side with its center eccentric to the casing. Most often this makes the job extremely difficult for a pilot mill. Under these conditions, we recommend a full gauge junk mill. A pilot mill will do a reasonable job on drill collars, provided the cuttings can be removed as the milling progresses. If cuttings tend to fall into the ID and plug it, then a junk mill must be used.

Using the Pilot Mill in Swaged Completion

The pilot mill is ideally suited to mill out the necked-down portion of casing in swaged completion. Necked-down lengths of casing, corresponding in length to the thickness of the producing zones, are made up with swages to the regular casing collars in the string. The casing is cemented and water shutoff is obtained at all zone intervals. The necked portions are then milled out with a pilot mill and the resulting sections are opened with an underreamer. This underreaming operation removes cement and wall cake, providing a clean producing area. 1. Lower the mill about five in. above the tubular. Set the brake and start rotating. Slowly increase rotation to 125 RPM. Raise and lower the mill three to six ft. but do not touch the tubular while rotating. This action will show the neutral torque to be determined. By noting the torque in the string when the pilot of the mill enters the tubular, you can determine if the pilot has been entered properly. 2. Reduce rotation to about 30 RPM and enter the pilot into the tubular. Apply 2,000 lb. of weight. Stop rotation quickly while you note the torque action of the string. A gradual slow down or spin indicates that the mill has entered the tubular with proper alignment.

Using a Pilot Mill

Downhole Milling
3. To mill H-40 or K-55 casing, use a weight between 4,000 and 6,000 lb. and a speed of 80 to 100 RPM, whereas N-80, P-110 and Q-135, etc. casing requires a weight of 8,000 to 10,000 lb. and a RPM of 100 to 120. If the casing is surrounded by hard cement, or if the open hole diameter is the same or less than the blade OD of the mill, more weight may be needed to drill cement and formation. When working below the shoe of the casing, ream the hole up and down after every 15 to 20 ft. of tubular milled to clean out any accumulation of cuttings which may have collected at the shoe. Periodic reaming to ensure cutting removal is also a good practice in holes with deviation of 30 degrees or more. 4. Normally, milling should be continued at an even rate without interruption once it has been started. Milling weight should be applied at a constant rate. Do not allow weight to drilloff.

25

Pilot Mill
Fishing neck diameter Top pin connection

Fishing neck length

Pilot diameter Blade diameter

26 Pilot Mill Specifications Blade Dia.

314 - 1378 418 - 1438 418 - 1538 512 - 1558 534 - 1738 618 - 1978 978 - 1712

Downhole Milling

Pin Conn. API Reg.

238 238 278 312 312 412 658

Pilot Dia.
134 - 1234 134 - 1234 218 - 1314 212 - 1434 212 - 1434 434 - 1634 734 - 15

Overall Length
27 27 27 38 38 42 45

Fishing Fishing Neck Neck Dia. Length

12 12 12 16 16 18 18 31 318 334 414 434 534 734

Wt. (lb.)
40 45 120 240 255 305 550

Notes: 1. All dimensions are given in inches unless otherwise stated. 2. All weights are approximate. 3. Standard API regular pin. Other sizes available upon customer request.

Ordering Instructions: When ordering or requesting quotations on pilot mills, please specify: 1. Size and weight of casing to be milled 2. Size and weight of casing to be run through, if available 3. Top pin connection

Downhole Milling Piranha Mill

Millmaster

27

Carbide inserts

Millmaster-dressed Piranha Mills are only available on a rental basis in conjunction with Smith job supervision. U.S. Patent Numbers: Carbide Insert Milling Tool 4,710,074 Piranha Mill 5,074,356

28

Downhole Milling

PiRAnhA Mill
The Piranha Mill is a tool which has been solely designed for the efficient removal of downhole casing strings. Millmaster technology ensures maximum ROP, ideal cutting size and extended milling duration.

Offshore Slot Recovery

Today, many fields are either reaching the end of their useful lives or are beyond the break-even point for production. Smith has worked closely with many major oil companies and their engineering divisions to develop a platform slot recovery system. This system provides an economical method to re-drill non-producing wells to a new target. Abandonment is eliminated by recovering existing slots. The main objective is the successful removal of the intermediate casing strings back to the surface string/conductor pipe. Depending on the quality of the casing cement job, a combination of retrieval and milling operations are normally employed. Where casing strings are cemented back to the casing spools, milling must be used exclusively. The need to remove the intermediate string of casing is carried out to expose a clear string of conductor pipe and formation around the shoe. This allows the well to be deviated as per normal practices.

Description of the Piranha Mill

The cutting structure consists of Millmaster carbide arranged in a brick pattern. The carbide, being specially developed for downhole application, prevents premature wear and breakage. The blade is manufactured from high-grade alloy steel and positions the cutting edge at the precise angle for maximum cutting efficiency. Extended blade length provides maximum footage per mill.

Slot Recovery Operating Parameters

As with all types of downhole milling, some specific guidelines must be followed to obtain optimum performance from the tool. The Millmaster cutting structure differs in its requirements from the conventional crushed tungsten carbide type. The two major components to be considered when deciding on parameters are RPM and weight-on-bit. The rotary speed is calculated as found on page 3 of the Data Handbook using the optimum cutting surface speed for tungsten carbide (250 to 340 ft/min.) vs. the outside diameter of the casing. The effective milling weights for the Piranha have been found to be in the range of 5,000 to 10,000 lb.

Downhole Milling Mill Stability

29

Stabilization is necessary to optimize the overall performance of the Piranha. An Ezy-Change sleeve-type stabilizer is included in the tools design. This allows the stabilizer to be changed at the rig site. Interchangeability is important, especially when milling eccentric casing strings. In deviated hole sections, or where a casing string has been forced to one side, the blade design will not skin the next casing string. Included in the stabilization is a standard taper mill, running directly ahead of the Piranha Mill and a stabilizer the same diameter as the Piranha Mill run immediately above the Piranha Mill. The taper mill is used to give the assembly the capability of clearing any junk or enlarging the stub of the casing. The OD and stabilization diameter is calculated to prevent damage to outer casing strings.

Piranha Mill Specifications Fishing Fishing Tool Casing Body Blade No. of Overall Wt. Top Pin Conn. Neck Neck Series Sizes Dia. Dia. Blades Length (lb.) Length Dia.
4500 5000 5500 6000 6600 7000 7600 8600 9600 10700 11700 13300 16000 412 5 2
1 1

434 4 4
3 3

5.250 5.813 6.300 6.875 7.640 7.906 8.750 9.875 10.875 12.000

3 3 3 3 3 3 5 5 5 5 5 5 5

312 IF BU 3 2 IF BU
1 1

12 12 12 12 12 12 18 18 18 18 18 18 18

434 434 4 4
3

36 36 36 42 42 42 48 48 60 60 60 72 72

100 110 120 150 175 190 250 275 300 325 375 400 425

5 2 612 6 8
5

4 4 434 5 4
3 3

3 2 IF BU 312 IF BU 4 2 IF BU
1

434 5 4
3 3

5 4 614 6 4
3

4 2 Reg. BU
1

5 4 614 6 4
3

758 8 8
5

412 IF BU 5 2 Reg. BU
1

958 10 4
3

812 9 2
1 1

658 Reg. BU 7 8 Reg. BU

5 5

812 9 2
1

11 4
3

10 4 13.000 1112 14.625 14 2 17.250

1

8 8 Reg. BU 858 Reg. BU 8 8 Reg. BU

5

10 4
1

1338 16 2
1

1112 14 2
1

Notes: 1. All dimensions are given in inches unless otherwise stated. 2. All weights are approximate. 3. Pilot stabilization dressed to casing drift diameter. 4. Guide mill or taper mill dressed to casing drift diameter. 5. Ezy-Change II stabilizer sleeve available on casing sizes 758 in. and larger.

Ordering Instructions: When ordering or requesting quotations on Piranha Mills please specify: 1. Tool series 2. Size and weight of casing to be milled 3. Top pin connection

30 Junk Mill

Downhole Milling

Conventional

Conebuster

Super

Dressing Options

Downhole Milling

31

JunK Milling
The junk mills chew their way through the toughest materials. Junk mills are said to be the true workhorse of downhole milling operations. When drill pipe is cemented inside and out, a junk mill is the only tool that will do the work. However, if the drill collars or drill pipe are not collapsed and the ID is open, a pilot mill can sometimes be used to better advantage. When casing has been milled with a pilot mill or section mill to the point where it begins to rotate, it can often be pounded down and milled using a junk mill made up at the end of a joint of slightly eccentric or bent drill pipe. Junk mills can be used to mill almost anything in the hole, including cement and rubber products. 1. Tag bottom and pick up three ft. Begin circulating as for normal drilling conditions. 2. Begin rotation at 60 to 80 RPM. 3. Apply weight at 4,000 RPM. 4. If there is an indication junk may be turning, spud two or three times. 5. After milling one to two ft., pick up the kelly 15 to 20 ft. off bottom and reduce pump pressure or shut off pumps (depending on hole conditions). This action will let the loose junk settle to the bottom. 6. Once again feel for the bottom and spud. Begin rotation at 80 to 100 RPM using normal pump pressure. Begin weight at 4,000 to 6,000 lb. 7. Repeat steps three and four every few feet. Procedures from here on will be governed by feel.
Note: In hard formation it will take fewer feet of the hole to mill up the junk than in softer formation. This difference is due to the junks ability to lodge itself into the softer formation.

Junk Milling Procedures

General Guidelines

When milling loose junk, operations can be improved by frequent spudding. This action will pound the junk onto the bottom, positioning it for more effective milling. Never permit a sliver or piece of junk to lodge next to the mill. Force it down by spudding the mill. A noticeable increase in torque will indicate that a sliver or piece of junk is alongside the mill. Picking up the mill and lowering it periodically will decrease the possibility of a deep wear pattern developing, thus evening the wear on the mill face. When milling cast-iron bridge plugs, the mill OD should be approximately 1 8 in. under the size of the bridge plug this will prevent skinning the casing.

32 Loose Junk in Open Hole

Downhole Milling

Use a junk mill with an OD of 1 8 in. less than hole diameter. Use at least 10,000 lb. of drill collars. Run a junk sub directly above the mill. In soft formation consider the use of a Junk Master to prevent inadvertant sidetracking.
Note: Junk subs for 43 4 in. along with smaller drill collars are not strong enough for repeated spudding.

Frequent spudding improves milling efficiency on loose junk. To spud the junk and force it down, proceed as follows: 1. Determine the neutral or zero point. Mark the kelly at the top of the kelly bushing. 2. Pick up the kelly four to six ft. (four ft. in shallow holes, six ft. in deeper holes). 3. Drop the kelly and catch (not slow down, but catch it) with the brake about 18 to 20 in. above the zero mark. (Example: Pick up ten ft. and drop it 81 2 ft.) This action causes the drillstring to stretch and spud the junk on bottom with great force while the string is still in a state of tension. This prevents damage to the string which might be expected if the string is in compression at the moment of impact. 4. Spud the junk three or four times, turning the mill a quarter-turn each time between drops. Use a junk mill with a diameter about 1 8 in. less than the hole diameter. Mill with 4,000 to 10,000 lb. of weight, depending upon the strength of the junk being milled. After three to five ft. of junk milled, pick up the mill ten to 15 ft. and ream the hole down to the junk. After reaming the hole down, always set down on the junk while turning and bring the weight up to milling weight. Never apply weight first and then start rotating.

Stationary Junk in Open Hole

Loose and Stationary Junk in Open Hole Procedures for running a junk mill inside the casing are the same except for the following:

Run a stabilizer directly above the mill which has the same OD as the mill. The mill head OD should be the same as the drift diameter of the casing. Wear pads having the same OD as the diameter of the mill head are provided on the junk mill. These will eliminate possible damage to the casing.

Downhole Milling Junk Mill

Fishing neck diameter

33

Top pin connection

Fishing neck length

Dressed diameter

34 Junk Mill Specifications Standard Cutting Dia.

312 - 412 4 2 - 5 2
1 1

Downhole Milling

Overall Length Junk Mill Top Pin Conn and Cone Super Fishing API Reg. Buster Junk Mill Neck Length
238 2 8
7

Fishing Wt. (lb.) Neck Dia.

3 3 4
3

20 21 23 23 27 29 30 33 37
5

20 21 21 21 27 29 30 33 37

12 12 12 12 12 12 12 12 12
3

45 62 95 105 180 350 500 625 1,200

1

512 - 558 5 4 - 7 2
3 1

312 3 2
1

414 4 4
3

712 - 9 9 2 - 12 4
1 1

412 6 8
5

534 7 4
3

13 - 15 17 - 17 2
1

658 or 758 6 8 or 7 8
5

734 or 912 7 4 or 9 2 734 or 912

1812 - 26

658 or 758

Notes: 1. All dimensions are given in inches unless otherwise stated. 2. All weights are approximate. Ordering Instructions: When ordering or requesting quotations on junk mills, please specify: 1. Mill diameter 2. Size and weight of casing to be run through, if available 3. Top connection

Downhole Milling Junk Sub

Bore diameter Fishing neck diameter Top pin connection

35

Body diameter under sleeve

Sleeve length Mud bleed holes

Bottom box connection

Body diameter

36

Downhole Milling

JunK SuBS
Junk subs capture and trap junk too heavy to circulate. They are designated to be used in the drill collar string just above the rock bit or milling tool. The tool consists of a steel mandrel with an oversized sleeve or skirt attached over the mandrel. The skirt is welded at the lower end. The skirt will trap the large cuttings and junk which are too heavy to be circulated out the hole. The skirt is manufactured with bleed holes to allow the mud to drain once it is brought out of the hole. It is recommended that two junk subs be run in tandem to decrease the possibility of junk bypassing a single junk sub. A stabilizer should be run above the junk subs to reduce bending through their bodies.

Junk Sub Specifications Top and Body Dia. Bottom Conn.

358 4 4 412 5 512 612 658 6 4
3

Overall Length
33 33 37 37 38 38 48 48 48 48 50 50 50 51 51

Fishing Neck Dia.

3116 312 3 8
5

Body Dia. Under Sleeve

2 212 2 2
1

Bore Dia.
1 114 1 4
1

Sleeve Length
12 12 12 12 12 15 15 15 15 15 15 15 15 15 15

Wt. (lb.)
50 62 66 91 120 144 261 270 280 298 438 451 529 806 1,065

238 238 2 8
7

278 312 312 412 412 4 2

1

378 438 458 578 578 5 8

7

212 314 314 412 412 412 412 5 4

3

114 112 112 2 2 2 2 2 16

13

7 8 2
1

412 6 8
5

6 7 2
1

858 958 10 4
3

658 658 7 8
5

712 812 9 8
5

534 534 7 8
5

21316 21316 3 3

1234

758

1158

758

Notes: 1. All dimensions are given in inches unless otherwise stated. 2. All weights are approximate. 3. Standard API regular connections. Other sizes and lengths available upon customer request.

Ordering Instructions: When ordering or requesting quotations on junk subs, please specify: 1. Tool size 2. Top and bottom connections

Downhole Milling Taper Mills

37

CP

tAPeR MillS

CT

Taper mills are generally used to eliminate restrictions or to mill through pinched or collapsed casing. They are equipped with a tapered or a short blunt nose which serves as a guide. Smith offers a CP taper mill or a CT taper mill.

CP Taper Mill Designed for the Toughest Taper Mill Job

The CP taper mill features a blunt-nose design that makes it useful in those taper milling applications where the possibility of using a longer tapered nose might break. The CP mill generates considerably less torque than a conventional taper mill because of its shorter taper section. Because of this low-torque feature, the CP mill can be run with more weight when necessary.

CT Taper Mill Perfect for Milling Restrictions

The CT taper mill was designed for milling through restrictions. The spiral blades and the pointed nose make the CT ideal for reaming out collapsed casing and liners, cleaning up permanent whipstock windows, milling through jagged or split shoes and enlarging restrictions through retainers and adapters.

38 General Guidelines for Using a Taper Mill

Downhole Milling

Start rotation at 75 RPM above the collapsed area. Taper milling RPM is governed by torque. To overcome torque problems, maintain at least 75 RPM. Use less weight when running a taper mill than a junk or pilot mill. After you have entered the collapse, increase the weight slowly from 1,000 to 2,000 lb. Watch for any torque increase. 1. Use a taper mill of the same diameter as the largest mill used to mill the window (or slightly larger than the bit to be used). 2. Run the taper mill into the hole to within five ft. from the top of the window. 3. Rotate slowly 40 RPM, down the full length of the whipstock. Do not attempt to make hole using this tool. 4. Keep weight under 1,000 lb. Excessive weight may cause the taper mill to slip out of the window prematurely. 5. To clean up all rough edges, repeat the above procedure several times until the mill runs smoothly for the full length of the whipstock which is indicated by minimal torque. 1. Determine the approximate diameter using a bit that will pass through the collapsed interval. Do not use a taper mill if the collapsed interval has passed center. 2. Use a taper mill about 1 4 in. larger than the minimum ID of the collapse and mill out in stages. In other words, if the collapse is great, use several different sizes of mills to bring the ID of the pipe to full gauge. This will minimize any tendency to sidetrack. 3. A string taper mill can be used if there is any danger of sidetracking. 4. Begin milling at a table speed of about 50 RPM. 5. The milling weight is governed by the torque encountered. In most cases, milling weights of around 2,000 to 3,000 lb. are used. 6. Where the pipe is greatly collapsed, the lower portion of the collapsed interval may act as a whipstock. The taper mill, in this case, may cut through the upper portion of the collapsed interval and be deflected into the formation by the lower section of the damaged casing. In some cases of extreme collapsed pipe, it is better to run a stabilized, rigid hookup with a junk mill. Use very light weight with a table speed of about 125 RPM to mill out the collapsed portion and enter the undamaged casing below.

How to Clean Up Whipstock Windows Using a Taper Mill

Procedures for Reaming Out Collapsed Casing

Downhole Milling Enlarging Restriction Through Retainers and Adapters

39

1. Use a taper mill with a diameter equal to the desired enlargement (usually the drift ID of the casing). 2. Mill about 70 RPM and with weight from 2,000 to 6,000 lb. Both the speed and the weight should be governed by the torque. If the torque is high, speed and weight should be reduced until the mill turns with minimal torque. 3. After milling through the restriction, increase speed to between 80 and 100 RPM. Rotate up and down through the interval several times until it is smooth and nearly torque free.

Using a Taper Mill to Ream Out Guide Shoes

In some cases, the bull plug on the bottom of liners or casing may be jagged or split to such degree that the string hangs up coming out of the hole. This condition can be remedied by reaming through the guide shoe with a taper mill. Follow the procedure recommended above for enlarging restrictions through retainers and adapters.

CP/CT Taper Mill

Fishing neck diameter Top pin connection

Fishing neck diameter Top pin connection

Fishing neck length

Fishing neck length

CP
Dressed diameter

CT

Dressed diameter

40 Taper Mill Specifications Dressed Dia.

13 4 - 13 8
1 7

Downhole Milling

Pin Conn. API Reg.

2 8
3 3

Overall Length CT
34 34 38 42 44 46 54 54

CP
30 30 31 32 32 34 36 36 36 38 40 60 60 66

Fishing Fishing Neck Neck Dia. Length

10 10 10 13 13 13 13 14 14 14 14 18 18 18
3 3

Wt. (lb.) CT
80 90 106 155 160 170 250 280

CP
60 70 75 115 120 130 185 220 280 355 390 460 530 1,125

3 3 8
1

14 - 4 8
3

2 8 278 312 312 312 4 2

1

1412 - 1538 1512 - 1558 1534 - 1638 1612 - 1738 17 2 - 17 8

1 7

334 414 434 434 5 4

3

1838 - 1912 19 8 - 19 8
3 7 1

412 4 2 or 6 8
5

534 5 4 or 7 4
3

54 57 60 70 70

345 415 455 525 595

1038 - 11 11 2 - 12 4
1 1

658 6 8
5 5

734 7 4
3 3

14 4 - 15
3

6 8 658 6 8 or 7 8
5 5

7 4 734 7 4 or 9 2
1

17 - 1712 20 - 26

76

1,250

Notes: 1. All dimensions are given in inches unless otherwise stated. 2. All weights are approximate.

Downhole Milling

41

SPeCiAl MillS
Economill
Economills are a low-cost alternative for light-duty milling jobs. Dressed with tungsten carbide, Economills are an effective tool for milling packers, retainers, bridge plugs and cement. Manufactured with standard API connections, the mill is made up and broken out with a standard bit breaker. No additional subs are required. Circulation is directed along each cutting blade and through the center of the head for proper cutting removal and cooling. Stabilizing ribs immediately above the cutting blades prevents damage to the casing.
Note: Economills are fabricated from a casting and should not be used as junk mills. The cast products do not have the same material strength!
Top pin connection

Dressed diameter

Economill Specifications Tool Series

3000 4000 5000 7000 10000

Dressed Dia.
314 - 438 4 2 - 5 8
1 3

Top Pin Conn. API Reg.

238 2 8
7

Overall Length
758 8 8
5

Wt. (lb.)
17 26 40 76 125

Recommended Torque (ft/lb.)

3,000 - 3,500 6,000 - 7,000 7,000 - 9,000 12,000 - 16,000 28,000 - 32,000

512 - 738 7 2 - 8 4
1 3

312 4 2
1

9 11 2
1

1014 - 1214

658

1612

Notes: 1. All dimensions are given in inches unless otherwise stated. 2. All weights are approximate.

Ordering Instructions: When ordering or requesting quotations on Economills, please specify: 1. Mill dressed diameter 2. Size and weight of casing to be run through, if available 3. Protective subs available upon request

42 Drillmill

Downhole Milling

The cast Drillmill is a rugged tubing mill designed for reaming hardened cement, sand and scale out of tubing or drill pipe with maximum efficiency, even when wireless and other light junk inside the tubing or pipe must be milled simultaneously. A wall contact area of three square inches ensures proper stabilization and eliminates possible damage to tubing or pipe walls Drillmills are available for all sizes of tubing and drill pipe and can be supplied in a wide selection of drill rod tool joints.
Top pin connection

Wall contact area 3 in.2

Dressed diameter

Drillmill Specifications Series Number

2800 3800

Length
538 538

Dressed Dia.
134 - 3 234 - 378

Standard Pin Connections*

Drill rod: A, B, AW, EW, E Drill rod: N, NW

* Other connections made to customer specifications can be furnished. Note: All dimensions are given in inches unless otherwise stated.

Downhole Milling Junk Master

ID Top pin connection

43

Fishing neck diameter

Fishing neck length

Skirt ID Skirt OD

44 Junk Master

Downhole Milling

Junk Master is a three-piece, demountable skirted junk mill. It is the ideal tool for milling inside casing or milling up torn or plugged tubular junk. The three-piece design of the Junk Master-driver sub, Economill and skirt, permits a worn part to be replaced without discarding the complete tool. The thrifty Economill can be replaced for a fraction of the cost of a one-piece skirted junk mill. The skirt slips over distorted or split pipe and the fish to protect the casing while keeping the Economill from slipping off the top of the fish. Four designs are available: Tooth type, V-notch, perforated type or fishing lip type. Both the Economill and skirts are dressed with tungsten carbide.

Three-piece Skirted Junk Mill Specifications Tool Series

3500 4000 4500 5700 7000 7600 10700 11700

Skirt OD*
312 458 4 2
1

Skirt ID**
278 378 3 4
3

Top Pin Conn. API Reg.

238 278 2 8
7

Fishing Neck Dia.

314 334 3 4
3

Length (ft.)
46 46 46 47 47 47 59 59

Wt. (lb.)
45 70 80 110 165 220 368 417

534 758 734 10 4

3

558 534 612 9 8

3

312 412 412 6 8

5

434 534 534 7 4

3

1134

1038

658

734

* OD of skirt can be dressed larger. ** ID of skirt can be dressed smaller. Notes: 1. All dimensions are given in inches unless otherwise stated. 2. All weights are approximate. 3. Standard API regular connections. Others available upon customer request. Ordering Instructions: When ordering or requesting quotations on the Junk Master, please specify: 1. Dressed OD and ID of skirt 2. Size and weight of casing to be run through, if available 3. Tooth design of skirt (Tooth type, V-notch, perforated type or fishing lip type, etc.) 4. Top connection

Downhole Milling

45

tungSten CARBiDe PRoDuCtS

Since the early 1950s, we have been providing our customers with the necessary hardmetal and dressed tools to effectively perform their operations. Only the highest quality carbides are selected for all the tungsten carbide products.

Tungsten Carbide S An S grade carbide is composed of tungsten, titanium and tantalum carbides as a binder.
The tungsten carbide rod is made up of sharp particles of tungsten carbide suspended in a resilient nickel-silver alloy matrix. This matrix protects the carbide from extreme shock conditions while exposing new sharp edges for the cutting operation. The rod is deposited to the base material with an oxy-acetylene torch. Tungsten Carbide S is available in concentrate form (approximately two lb. rod bare) or composite (approximately 11/2 lb. rod, flux coated or bare. Kits are available, including tungsten carbide, with the necessary flux and tinning rod to prepare the base metal before application (see tables on page 48).

Tungsten Carbide Rod Application

1. The material to which tungsten carbide is to be applied should be thoroughly cleaned and be free from corrosion and other foreign matter. Grit blasting is the preferred method, but grinding, wire brushing or sanding is also satisfactory. 2. Arrange the work area so the tool is positioned for down hand welding; when possible, secure the tool in a suitable turning jig fixture. 3. Staying three to four in. off surface, slowly preheat to approximately 600F (316C) to 800F (427C); maintain a minimum of 600F (316C). 4. Use a spoon or spatula to sprinkle the surface to be dressed with brazing flux. The flux will bubble and boil if the surface of work piece is sufficiently heated. This flux will help to prevent the formation of oxides in the molten matrix during dressing. 4.CAUTION: Make sure that the working area is well ventilated so that any gases generated from the flux or filler are carried off and away from the welder. These gases are toxic and prolonged inhalation may produce nausea or sickness. The welder must wear a face shield, long sleeves and gloves during application.
Note: Sandblasting the surface will cause difficulty in tinning.

46

Downhole Milling
5. Use an oxy-acetylene torch; tip selection will depend upon situation: No. 8 or 9 for dressing large areas; No. 5, 6 or 7 for smaller areas or tight corners. Adjust the torch flame to a low-pressure neutral flame, one in which the light blue excess acetylene feather just disappears. 6. Continue to heat the surface to be dressed until the brazing flux is fluid and clear. 7. Staying three to four in. off surface, localize the heat in one area to a dull cherry red, 1,600F (871C). Begin tinning by melting on about 1 32 to 1 16 in. thick cover of filler rod. If the surface is hot enough, the filler rod will flow and spread to follow the heat; if not, the molten metal will bead up. Continue to heat and tin the surface to be dressed as fast as the molten filler metal will bond. 8. Separate tungsten carbide composite or concentrate rod into small pads, 1 2 to 1 in. sections. This can be done by heating a rod on a non-stick surface (carbon block) until the matrix becomes molten. 9. For easier handling, heat the composite of concentrate rod and tack the filler rod to the pad. Dip the rod in the brazing flux, heat tinned surface with torch and place the tungsten carbide piece in position. Heat tungsten carbide and base steel just enough to melt the matrix, then move the torch away from the surface, continuously moving across the area to keep the matrix molten. The filler rod is used to help position the carbide for proper concentration. CAUTION: Do not use excessive amount of filler rod as it will only dilute the carbide. Do not overheat carbides or matrix. Never permit the dark blue inner cone of the flame to contact the carbide as the heat is too high in this portion of the flame. If carbides refuse to tin, they must be flipped out of the puddle and kicked off. 10. Both tungsten carbide composite and concentrate rods are available in a number of graded fragment sizes; the desired buildup can usually be made with a single layer of the correct particle size. More experienced welders prefer to apply one layer, float it and then apply a second. The deposit thickness should never exceed the thickness of the steel being dressed. Proper application and positioning will reduce the amount of grinding necessary for sizing. 11. After each blade has the proper amount of tungsten carbide dressed, apply a light overlay of filler rod. Use care and do not heat the carbides or matrix already in place. 12. Once dressing is complete, cool the tool slowly in vermiculite. Never cool with a liquid. Do not reheat the dressed area by performing any welding near it.

Downhole Milling Tungsten Carbide Removal

47

When removing tungsten carbide dress, use the same size torch tip used in the application. Heat the tungsten carbide until it is just molten, then flip it off the surface using a suitable rod. CAUTION: Under no condition should the operator attempt to melt the tungsten carbide enough to make it flow or run off. Never attempt to re-use tungsten carbide which has been previously used or applied.

Tungsten Carbide Furnace Products Carbide Concentrate Rod 1/ x 1 x 151/ 2 2 Wt. (lb.)
3 5 1 3 1

Composite Rod 3/ x 15 8 Wt. (lb.)

0.76 0.53 0.53 0.53 0.53 0.53

8 x 38 16 x 4
1

2.0 2.0 2.0 1.88 1.5 N/A

4 x 316 16 x 8
1

8 x 116

10/20 Mesh Notes: 1. All dimensions are given in inches unless otherwise stated. 2. All weights are approximate.

Ordering Instructions: When ordering or requesting quotations on tungsten carbide furnace products, please specify: 1. Composite or concentrate rod 2. Quantity (lb.) 3. Carbide particle size 4. Tinning rod and flux quantities (20 lb. tinning rod and five lb. flux per 100 lb. composite)

48 Tungsten Carbide S Field Kits Mills Kit Number

J6 J7 J8 J9 J10 J12 J14 J17

Downhole Milling

Size and Type Kit Will Redress (in.)

(1) 6 in. junk mill or (2) 412 in. junk mills or (1) 5 in. pilot mill (1) 758 in. junk mill or (2) 558 in. junk mills or (1) 6 in. pilot mill (1) 858 in. junk mill or (2) 6 in. junk mills or (1) 712 in. pilot mill (1) 958 in. junk mill or (2) 758 in. junk mills or (1) 812 in. pilot mill (1) 1058 in. junk mill or (2) 814 in. junk mills (1) 1214 in. junk mill or (2) 858 in. junk mills or (3) 758 in. junk mills or (1) 12 in. pilot mill (1) 15 in. junk mill or (2) 1058 in. junk mills or (1) 15 in. pilot mill (1) 1712 in. junk mill or (2) 1214 in. junk mills or (1) 1712 in. pilot mill

Tungsten Carbide S Field Kits Washover Shoes Mills Kit Number

W5 W6 W7 W8 W9 W10 W11 W12

Size and Type Kit Will Redress (in.)

(1) 5 in. OD shoe (1) 6 in. OD shoe (1) 7 in. OD shoe (1) 8 in. or (2) 5 in. OD shoes (1) 9 in. OD shoe (1) 10 in. or (2) 6 in. OD shoes (1) 11 in. or (3) 5 in. OD shoes (1) 12 in. OD shoe

Ordering Instructions: When ordering or requesting quotations on tungsten carbide S field kits, please specify: 1. Number of kits 2. Kit number

48 Tungsten Carbide S Field Kits Mills Kit Number

J6 J7 J8 J9 J10 J12 J14 J17

Downhole Milling

Size and Type Kit Will Redress (in.)

(1) 6 in. junk mill or (2) 412 in. junk mills or (1) 5 in. pilot mill (1) 758 in. junk mill or (2) 558 in. junk mills or (1) 6 in. pilot mill (1) 858 in. junk mill or (2) 6 in. junk mills or (1) 712 in. pilot mill (1) 958 in. junk mill or (2) 758 in. junk mills or (1) 812 in. pilot mill (1) 1058 in. junk mill or (2) 814 in. junk mills (1) 1214 in. junk mill or (2) 858 in. junk mills or (3) 758 in. junk mills or (1) 12 in. pilot mill (1) 15 in. junk mill or (2) 1058 in. junk mills or (1) 15 in. pilot mill (1) 1712 in. junk mill or (2) 1214 in. junk mills or (1) 1712 in. pilot mill

Tungsten Carbide S Field Kits Washover Shoes Mills Kit Number

W5 W6 W7 W8 W9 W10 W11 W12

Size and Type Kit Will Redress (in.)

(1) 5 in. OD shoe (1) 6 in. OD shoe (1) 7 in. OD shoe (1) 8 in. or (2) 5 in. OD shoes (1) 9 in. OD shoe (1) 10 in. or (2) 6 in. OD shoes (1) 11 in. or (3) 5 in. OD shoes (1) 12 in. OD shoe

Ordering Instructions: When ordering or requesting quotations on tungsten carbide S field kits, please specify: 1. Number of kits 2. Kit number

Whipstock Operations

49

Whipstocks
Due to the increased cost of drilling, technology for sidetracking has rapidly accelerated. The tool used in this application is referred to as a whipstock. Today most whips are retrievable, whether they are a packer-type, anchortype or mechanical-set bottom trip. With more and more multilaterals being drilled, the whipstock generally suits this application. In the future, milling assemblies will be capable of setting the whip, milling the window and drilling as much as 500 to 1,000 ft. of new hole. Sidetracking is and will continue to be a very important part of well drilling, whether it is for enhanced oil recovery, exploration, redrilling or utilizing an old well in multilateral applications.

RetRievable pack-stock
This system, developed through years of experience, is a one-trip, combination packer/whipstock sidetracking system. Its a patented tool that offers significant advantages over the original, mechanically set whipstocks prevalent since the 1930s, and its an attractive alternative to conventional sidetracking procedures. The Pack-Stock system yields significant savings in both time and cost. Its ideal for sidetracking cased holes during re-drill or re-entry in old or marginal wells. The Pack-Stock can be set at any depth, immediately above a casing collar. The system offers substantial advantages over the conventional two-trip whipstock/packer assembly: Economical and efficient one trip to locate packer depth, orient, set packer and start milling. The custom-designed packer prevents movement or rotation of the PackStock. Clearance provided minimizes hole-swabbing or hang-ups. The shear bolt ensures setting of the packer prior to milling. A large slip area reduces casing stress and provides a more positive anchor set. The ability to mill through two strings of casing. A proven three degree face angle to provide positive kickoff, regardless of formation or hole angle. Retrievable in one trip.

Operational Recommendations

The Pack-Stock system is run in the hole to depth on a starter mill. For a preferred angle or direction, a muleshoe sub can be run and surveyed with an orienting device. If orientation in a specific direction is required, or if the hole angle will exceed four degrees, the Pack-Stock assembly should be set 90 degrees or less to the right or left of the holes high side.

50

Whipstock Operations

Retrievable Pack-Stock Pack- Length Body Packer Whipstock Bypass Valve Stock OD Length Face Face Wt. Length OD Wt. Length Angle (lb.) (lb.) ()
512 758 758 958 13 8
3

182 216 229 261 338

4316 558 51516 858 11 4

3

76 84 84 84 87

106 133 146 178 251

3 3 3 3 3

585 980 1,400 2,500 6,595

25 43 43 46 38

338 434 434 634 8 4

1

40 150 150 240 400

Notes:

1. All dimensions are given in inches unless otherwise stated. 2. All weights are approximate.

Retrievable Pack-Stock

Whipstock Operations

51

RetRievable anchoR-stock
When a packer is not required, the hydraulically set Anchor-Stock casing sidetrack system can be used. It is a combination whipstock and anchor. The custom-designed anchor meets the same operating criteria as the Pack-Stock packer except for hole sealing; it is also very cost-effective. The procedure for using an Anchor-Stock hookup is identical to that for a Pack-Stock system. Fewer hole cleaning problems because cutting a window with the AnchorStock system removes only five percent of the metal required for a 60 ft. section. Retrievable in one trip. No troublesome plugs to set. Less time required to complete a job; packer (or anchor), starter mill and whip in one trip. Typical cost is less than a section milled below 10,000 ft. The Anchor-Stock system also offers these user benefits when compared to conventional, two-trip whipstock and packer assembly systems: Custom-designed anchor utilizes one-piece mandrel with anti-rotation keys, locking tapers between the cone and slips, and ratchet ring to prevent rotation or vertical movement of the whipstock. Larger slip area reduces casing stress and provides a more positive anchor. A strong shear bolt verifies complete setting of the packer prior to milling. This system must be run in the hole to depth on a starter mill. If you have a preferred angle and direction for the sidetrack, a muleshoe sub may be run and surveyed with an orienting device. If orientation in a specific direction is required or if the hole angle exceeds four degrees at setting depth, we recommend that the Anchor-Stock assembly be set not more than 90 degrees to the right or left of the holes high side.

Two Other Unique Advantages

With an Anchor-Stock system, you can also: Mill through two strings of casing. All whipstocks have a proven three degree face angle to provide positive kickoff regardless of formation or hole angle.

52

Whipstock Operations

Retrievable Anchor-Stock Anchor- Length Body Anchor Whipstock Stock OD Length Face Face Wt. Length Angle (lb.) ()
512 758 758 8 8
5 5

Bypass Valve Length OD Wt. (lb.)

40 150 150 150 240 400

165 197 210 229 241 322

43169 59116 5 3 89 7 89
1 1

74 95 107 124 142 212

3 3 3 3 3 3

535 895 1,380 1,875 2,285 6,200

25 43 43 43 46 38

338 434 434 434 6 4

3

63349 64 49
3 3

51516 63349 8 89 117 89 64 49 711 89

9 8 1338

814

Notes:

1. All dimensions are given in inches unless otherwise stated. 2. All weights are approximate.

Retrievable Anchor-Stock

Whipstock Operations

53

anchoR-stock/pack-stock Running pRoceduRe

1. Make gauge ring and casing scraper run utilizing a watermelon mill. Make collar locator run or cement bond log if cement bond is questionable. (Bottom of Anchor-Stock must be set two to six ft. above collar.) 2. As an option, if the casing is unbonded, a block squeeze should be considered at this point because if left unsupported will cause excessive vibration and hamper milling performance. Squeeze the zone around the kickoff point or move to step three. 3. Condition mud to provide good milling parameters and weight required to drill new hole section. Pull out of hole. 4. Pick up one joint of high-grade drill pipe. 5. Pick up whip running assembly and Anchor-Stock. 6. Pick up assembly and scribe a line to align the face of the Anchor-Stock along the assembly to the orientation sub; orient sub with the scribed line. Drill collars and Hevi-Wate IDs must be checked for proper clearance for orienting tools. Note: Depending on depth and angle, drill collars and Hevi-Wate can be reduced or eliminated from the Bottom Hole Assembly (BHA) and run with straight drill pipe with hydraulically set Anchor-Stocks or Pack-Stocks. 7. Trip in hole slowly to setting depth, monitoring hole drag. 8. At depth work string up and down to work out torque. 9. Orient Anchor-Stock to your specification. (Either run surface readout gyro or multi-shot surveys.)

10. Gradually apply 3,000/3,500 psi pressure and hold. 11. Work shear bolt up and down four to five times. Shear off Anchor-Stock. 12. Make starter mill cut out. 13. Pull out of hole, lay down starter mill and running assembly. 14. Trip in hole with Tri-Mill system on drill collars or drill pipe to clean and elongate window and drill four to six ft. of formation. 15. Pull out of hole. Lay down Tri-Mill.

Note: Do not rotate a bit or stabilizer down the face of the whip. If window is to be squeezed it must be reopened with a window mill, not a roller cone bit.

54

Whipstock Operations

RetRievable econo-stock
The Econo-Stock is a retrievable, mechanically set whipstock that offers substantial design improvements over competing products. Activation occurs when 3,600 lb. of weight are set down after a trigger rod contacts a plug in the casing. Applying additional weight sets the anchor and shears the starter mill bolt. The starter mill and shear bolt block are newly designed features. A shear-down shoulder prevents the starter mill from jamming and enhances the setting of the anchor. Multiple slips provide excellent load and torque capacity. The slips are held in position by a ratchet ring that provides equal loading in all directions. To release the anchor, the whip is engaged using the same retrieving tool as the field-proven Retrievable Anchor-Stock. An upward pull releases the anchor, and the slips fully retract as the tool is pulled from the well. Unlike many competing economy tools, the Econo-Stock provides a full complement of important benefits: Anchor setting requires no hydraulic pressure. Retrievable with conventional tools. Multiple tongue-and-groove slip design provides uniform stressloading on casing and maximizes anti-rotation capabilities. Simultaneously activated, full-contact slips centralize the anchor assembly in the casing. Retractable slips prevent casing drag during retrieval. Ratchet ring and nut ensure and maintain set. Bi-directional loading capability.

Whipstock Operations

55

standaRd econo-stock Running pRoceduRe

1. Make gauge ring and casing scraper run utilizing a watermelon mill. Make collar locator run or cement bond log if cement bond is questionable. (Bottom of Econo-Stock must be set two to six ft. above collar.) 2. If the casing is unbonded, a block squeeze should be considered at this point because if left unsupported will cause excessive vibration and hamper milling performance. Squeeze the zone around the kickoff point or move to step three. 3. Condition mud to provide good milling parameters and weight required to drill new hole section. Pull out of hole. 4. Pick up one joint of high-grade drill pipe. 5. Pick up whip running assembly and Econo-Stock in mouse hole. 6. Pick up assembly and scribe a line to align the face of the Econo-Stock along the assembly to the orientation sub; orient sub with the scribed line. Drill collars and Hevi-Wate IDs must be checked for proper clearance for orienting tools. Note: Depending on depth and angle, enough drill collar or Hevi-Wate weight must be calculated for shearing purposes when setting the Econo-Stock. 7. Trip in hole slowly to setting depth, monitoring hole drag. 8. At depth work string up and down to work out torque. 9. Orient Econo-Stock to your specification. (Either run surface readout gyro or multi-shot surveys.) 10. Apply 15,000 to 20,000 lb. of shear down force to shear bolt and set anchor. 11. Work BHA up and down to ensure shear bolt has sheared off the EconoStock. 12. Make starter mill cut out. 13. Pull out of hole, lay down starter mill and running assembly. 14. Trip in hole with Tri-Mill system on drill collars or drill pipe to clean and elongate window and drill four to six ft. of formation. 15. Pull out of hole. Lay down Tri-Mill. Note: Do not rotate a bit or stabilizer down the face of the whip. If window is to be squeezed it must be reopened with a window mill, not a roller cone bit.

56

Whipstock Operations

Retrievable Econo-Stock Retrievable Length Body Anchor Econo-Stock OD Length Whipstock Face Face Length Angle ()
74 95 124 3 3 3

Wt. (lb.)
570 875 1,175

5 512 7 8 8
5

14238 17218 189 2

1

4516 5716 7 16
7

3518 3818 43 2
1

Notes:

1. All dimensions are given in inches unless otherwise stated. 2. All weights are approximate. 3. Product can also be set permanently. 4. 758 and 958 in. Econo-Stock available upon request.

Retrievable Econo-Stock

Whipstock Operations

57

tips foR a successful Re-entRy

Whipstock Sidetracking
Casing Preparation Ensure that casing scraper, gauge ring and collar locator runs are made. Often the gauge ring and collar locator runs can be combined for efficiency. Cement Bond A cement bond log can be run if desired. A good cement bond enhances milling rates, but is not absolutely required for a successful sidetrack. Window Placement A sidetrack window can be located in any type of formation. If the formation is extremely consolidated, diamond mills may be needed to mill the window. It is imperative that the window not be cut through a casing collar. Try to position the bottom of the anchor or packer about five ft. above the collar. Hole Angle On holes with more than four degrees of deviation, the whipstock face should not be oriented more than 105 degrees to either side of the wells high side. Mud Properties Milling mud is not needed for a successful sidetrack, and many jobs have been completed using water. High-viscosity sweeps can be used periodically to clean the hole if desired. No specific annular velocities are needed due to the small quantity and fine size of the cuttings. Rig, Pump and Drillstring The rig must have sufficient capacity to handle the drillstring weight and have enough reserve capacity to shear the shear bolt.

The rig pump must have the capability to apply the 3,000 to 3,500 psi setting pressure to the drillstring. The drill pipe and rotation device (power swivel or rotary table) must have enough capacity to turn milling tools downhole without stalling. This will vary with depth of kickoff point and hole straightness. Generally, a 3.5 power swivel and 23 8 in. drill pipe is required for 51 2 in. casing, 31 2 in. drill pipe and a rotary table for 7 and 75 8 in. casing, 41 2 in. drill pipe and a rotary table for 85 8 and 95 8 in. casing, and 5 in. drill pipe and a rotary table for 133 8 in. casing.

58

Whipstock Operations

Milling Sequence The whipstock is run in hole and set on a starter mill. After setting, a shear bolt is sheared, separating the starter mill from the whipstock. Rotation is begun and the starter mill is slacked off until the tapered nose cams the tungsten carbide blades into the wall. It is imperative for the proper length of starter mill travel be attained to assure subsequent efficient milling runs. The window is then milled using a window mill. Run the window limber (one joint of drill pipe above the mill followed by drill collars). This will allow the window mill to flex off the face of the whipstock as it mills into formation. The window is then polished or elongated using a window mill and one or two watermelon mills run directly below the drill collars. Make enough open hole below the bottom of the window to provide adequate room for subsequent drilling assemblies. Post-Window Milling Precautions Never rotate a bit or stabilizer down the face of the whipstock. Treat a whipstock window as a casing shoe. Slack off and pull through the window slowly, carefully noting any unusual drag. If drag is encountered when running bent housing motors through a window, pull up, rotate the drillstring slightly and then slack off through the window. When the bend in the motor aligns with the whip, the BHA will pass through the window with minimal drag. General Planning Pre-job planning meetings (pre-spud meetings) to coordinate with the service companies involved in a sidetrack will result in a more efficient operation.

Whipstock Operations

59

tRackmasteR opeRations

Special meritorious engineering award for innovation and efficiency.

Trackmaster: The Only One-trip Window Milling System

The Trackmaster is the only full-gauge system that lets you open a sidetrack window in just one trip. Its a self-contained unit that reduces sidetracking costs by as much as 50 percent. In a single trip in and out of the hole, you accomplish all seven of the major steps needed for cutting a sidetrack window: Run the assembly. Orient the whipstock (with Measurement While Drilling (MWD)). Set the whipstock hydraulically. Shear the mill from the whipstock assembly. Mill and dress the window. Drill a full-gauge rathole. Pull out of the hole. The result is a full-size window completed in minimal time, providing a full-gauge rathole for the directional assembly. The Trackmaster system is available in a full range of sizes for 412 through 1338 in. casing. The system includes all necessary auxiliary equipment.

60

Whipstock Operations

Trackmaster System Description

The system is comprised of four major components: the bypass valve, running tool, milling tool and the whip assembly.

High-Flow Bypass Valve

The high-flow bypass valve performs several functions for the systems. First, it allows for circulation of drilling fluid so the whip assembly may be oriented with MWD. The high-flow bypass valve can then be closed to facilitate hydraulic setting of the anchor. Last, after shear-off, the valve closes each time circulation is started so all the drilling fluid goes to the mill where it is needed for cooling and cuttings removal. When not with a mud, a standard bypass valve may be used.

Running Tool

The running tool is used for the actual setting of the whip assembly. It provides a barrier between the drilling mud and the oil in the whip assembly to ensure the setting mechanism stays clean and free of debris.

Milling Tool

The milling tool includes three mills each with different objectives and dressed with high-performance carbide.

Lead Mill

The lead mill is a full-gauge mill designed to initiate the cut-out and mill the window further as it slides down the whip face. It also drills the rathole.

Follow Mill

The follow mill is also a full-gauge mill and engages with the casing as the lead mill travels down the ramp and elongates the window. The dress mill is a full-gauge mill and is designed to dress the window as the entire assembly passes through the casing. Each mill is dressed with Millmaster carbide for consistent and efficient milling performance.

Dress Mill

Whip Assembly

The whip assembly consists of a whipstock attached to an anchoring assembly. The whipstock has a multi-ramp design to guide the milling tool effectively and expediently through the casing and into the formation.

Whipstock Operations

61

Conclusions

Using Trackmaster will save time and money. MWD orientation eliminates the need for a wireline trip. The bypass valve controls drilling fluid for maximum efficiency of the Trackmaster components. Millmaster carbide on dressed mills ensures consistent and efficient window cutting. Note: The Trackmaster retrievable whip can be attached to any anchoring assembly, i.e., Pack-Stock, Anchor-Stock or Econo-Stock. These products provide you with the option of mechanical anchor, hydraulic packer or mechanical bottom trip. In addition, a big bore inflatable packer can also be attached to the whip for open hole application.

Anchor-Stock

Pack-Stock One-trip Sidetracking System

Econo-Stock (Bottom trip)

Trackmaster Whipstock

62

Whipstock Operations

Objectives

The objective of the Trackmaster is to accomplish the following steps in a single trip: Run the assembly. Orient the whipface (with MWD or gyro). Set the whip assembly (hydraulically). Shear the mill from the whip assembly. Mill the window. Drill the rathole. Pull out of hole. The result is a full size usable window with a minimum of milling time and a full-gauge rathole for the directional drilling assembly.

Whipstock Operations

63

tRackmasteR
Benefits
Eliminate starter mill run. Aggressive initial ramp to ensure quick efficient cut out. Millmaster technology for consistent milling performance. Mid-whip ramp to reduce core problems and milling time. Full-gauge mills to ensure full-gauge window and rathole. Entire procedure is finished in one trip into the hole.

Typical Running Assembly for 95/8 in. Trackmaster

MWD 63 4 in. OD

Bypass valve

63 4 in. OD

HWDP

5 in. OD 61 2 in. OD

Running tool 61 2 in. OD

Mill

Mill gauge 81 2 in. diameter

Whipstock

64 Notes:

Whipstock Operations

Concentric Hole Enlargement

65

Underreaming
Underreaming is the process of enlarging a section of wellbore beneath a restriction. The most frequently encountered restrictions are the inside diameter (ID) of the casing and the size of the wellhead. Both limit the maximum outside diameter (OD) of the tools that can pass through. The term hole opening is often used interchangeably with underreaming. Essentially, both operations enlarge the existing pilot hole. Hole opening involves enlarging the wellbore starting from the surface. Therefore, hole openers have cutters rigidly attached to the body on a fixed diameter. No hydraulic actuation is needed for the tool operation. Underreaming takes place at some point below the surface. Since the tool has to first pass through the restricted bore, it incorporates expandable cutters which stay collapsed while the tool is run in and once the tool has cleared the casing and wellhead, the cutters expand into the formation by utilizing the differential pressure of the drilling fluid or pneumatic medium. Once the hole is underreamed to the desired depth, the pumps are turned off, allowing the arms to collapse back into the body. The tool is then pulled out of the hole through the restricted section.

Application of Underreamers

Underreamers are used whenever it is necessary to open the diameter of a portion of the borehole, beginning somewhere below the surface. Typical applications include: Opening the hole below the casing shoe to provide a larger annular space for cementing the next casing string. This permits the use of a larger intermediate casing diameter than could be used otherwise. BOP or wellhead size restricts the tool diameter. Enlarging the hole annulus within the producing zone for gravel-pack completions. Opening a pocket to start a sidetrack. Enlarging heaving areas through problem fault zones. Reducing dogleg severity. Selection of an underreamer depends on the formation and on whether or not simultaneous drilling is required. Smith offers a Reamaster underreamer capable of simultaneous Underreaming While Drilling (UWD), a Drilling-Type Underreamer (DTU), a Rock-Type Underreamer (RTU) and a Drag-Type Underreamer (SPX).

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Concentric Hole Enlargement

General Guidelines for underreaminG

Formation Considerations
ROP of soft formation reacts better to rotary speed. ROP of PDC cutters react better to rotary speed. ROP of medium-hard formation reacts better to weight. Soft formations underream faster than the pilot-hole bit (25 ft/hr. average). Medium formations underream equal to the pilot-hole bit (10 to 25 ft/hr. average). Hard formations underream slower to the pilot-hole bit (10 ft/hr. average).

Maximum Weight on Tools with Milled Tooth/TCI Cutters

Drag-type 700 lb. x body diameter Rock-type 1,000 lb. x body diameter Drilling-type with bullnose 1,000 lb. x body diameter Drilling-type with bit 1,500 lb. x body diameter Reamaster with bit or bullnose 4,000 lb. x body diameter

Maximum Weight on Tools with PDC-type Cutters

Drag-type with SPX/PDC 500 lb. x number of PDCs Rock- and drilling-type with Bearclaw PDC 500 lb. x number of PDCs Reamaster-type with parabolic PDC 500 lb. x number of PDCs*
*This pertains to PDCs in contact with formation excluding redundant gauge coverage.

Anticipated Life of Cutters Cutter Life (hr.)

15 - 20 20 - 30 30 - 40 40 - 50 50 - 60 60 - 80 60 - 80

Crushed carbide Open roller Sealed roller Sealed journal SPX/PDC Bearclaw/PDC Reamaster/parabolic-PDC

Maximum RPM
180 130 140 100 140 180 200

Concentric Hole Enlargement

67

Optimum circulation rate is 35 GPM times underreamed diameter. Reamaster circulation rate is 50 GPM times underreamed diameter. Fluid velocity in the RTU/DTU and drag-type underreamers should not exceed 150 ft/sec. Fluid velocity in Reamaster underreamers should not exceed 75 ft/sec.

Tool Selection

In recent years Smith has made several improvements to underreamers. Several internal parts have been redesigned to improve performance, extend component life, reduce maintenance and decrease cost. Cutter arm selection has been expanded to include the following. Cutting Structures Tungsten carbide Milled tooth TCI (Tungsten Carbide Inserts) SPX-PDC (Polycrystalline Diamond Compacts) Bearclaw-PDC Parabolic-PDC Bearing Packages Open-roller bearing Sealed-roller bearing Sealed-journal bearing We can provide a variety of underreamers, depending on customer requirements and performance needs, either unaccompanied or with experienced operators who maximize tool performance. The cutting structures available for underreamers are illustrated on the following page.

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Concentric Hole Enlargement

DTU/RTU Underreamer Cutters

DS, K2

DT

DG, C4

V2

Bearclaw F1 TCI

Parabolic

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69

DTU/RTU Underreamer Cone Availability

IADC Code
Open (1) Sealed (4) Journal (6) Underreamer Series
3600 RTU 3600 DTU 4500 RTU 5700 DTU 5700 RTU 7200 DTU 8200 DTU 7200 RTU 8200 RTU 9500 DTU 8200 RTU 9500 RTU 11700 DTU 11700 RTU 15000 DTU 15000 RTU 17000 DTU 15000 RTU 17000 DTU 17000 DTU 22000 DTU 22000 RTU X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X

Milled Tooth 1-1

K2 K2 K2 DS DS DT C4

TCI 1-3
C4 DG F1 F2

1-2
DT

2-1 4-3 5-1

V2

IADC Code

Journal (7) Bit Cone Size (in.) 35/8 41/2 55/8 63/4 73/8 91/2 121/4 133/4 143/4 15 171/2

Note: Bearclaw/PDC or parabolic-PDC Superdome cutter heads may be fabricated for any of the above underreamers.

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Concentric Hole Enlargement

Reamaster (XTU)

Milled Tooth

TCI

Parabolic (PDC)

Cutter Types

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71

reamaster (Xtu)
Innovative Design Improves Underreaming
A major addition to the Smith line of underreamers, the Reamaster Underreamer* or XTU is the result of years of development and testing. The objective was to develop an underreamer that far exceeded the inherent limitations of conventional underreamers: low weight-carrying capacity, short bearing life and marginal hydraulics. The Reamaster tool has achieved these improvements and excels over conventional underreamers. It features: Sustained drilling weight equivalent to bit. Larger cones and bearings for extended on-bottom time. Enhanced hydraulics for better hole cleaning. Capable of simultaneous Underreaming While Drilling (UWD).

Substantially Reduces Overall Casing and Cementing Costs

Now you can save money by optimizing casing sizes on multiple string wells. The Reamaster underreamer is specifically designed to underream long intervals and provide the cementing space needed to run minimum clearance casing programs. You can design a slimmer top hole for a given diameter production zone or for a larger than standard production zone for a given hole size. Refer to the chart on page 73 to show possible combinations of casing with minimum clearance. Based upon recommendations provided by cementing firms and casing manufacturers, the chart assumes minimum clearance of less than 1 2 in. between outer string drift diameter and inner string coupling diameter for cased holes.
* Reamaster systems are only available on a rental basis in conjunction with Smith job supervision.

Features
One-piece Forged Arms One-piece forged arms with integral journals to hold cutters. Simple and strong internal components. Carry four to five times more drilling weight than conventional tools. Withstand high shock loads and torque downhole. Increase penetration rates. Positive lock keeps arms in open position. Feature large diameter single-hinge pin.

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Concentric Hole Enlargement

Customized Cutters

Cutters and cutting structures designed exclusively for underreaming. Cutters available with milled tooth, TCI or PDC cutting structures. Large sealed bearings. Milled tooth and TCI cutters are designed with compensated sealed bearings. Specially designed large cutters achieve lower RPM, resulting in longer bearing life. Optimum journal angle provided during drilling, plus other features, substantially increases bearing life for longer on-bottom time and increased penetration rates.

Improved Hydraulics

Unique internal design more than doubles allowable drilling fluid flow through the tool. Features four nozzles, two jetting directly on the bench and one on top of each cutter. Increases amount of hydraulic energy for better hole cleaning efficiency and faster penetration rate. Strategic placement of nozzles keeps cutters clean and cool.

Concentric Hole Enlargement

73

Recommendations to Set Small Clearance Consecutive Strings of Casings Outer Casing Size (in.)
24 20 16 133 8 (48 - 68 lb.) 113 4 (29.3 lb.) 85 8 (24 - 32 lb.) 85 8 (36 - 49 lb.) 75 8 7 (17 - 32 lb.) 95 8

Largest Inner Casing Size (in.)

20 16 133 8 103 4 85 8 75 8 65 8 6 51 2 5

Underreaming (in.) Min. Pilot Hole

181 2 171 2 143 4 121 4 105 8 83 4 75 8 73 8 61 4 6

Underreamed Dia.
26 22 171 2 15 121 4 111 2 91 2 9 81 2 8

Reamaster Tool Series

16000 16000 11750 11750 9500 8250 7200 5750 5750 5750

Note: Recommendations are based on: The minimum clearance of 0.400 in. on diameter between the outer string drift diameter and inner string coupling diameter. The clearance between the hole wall and the coupling OD is at least two in. on diameter. Less clearance than this may create a back pressure which will dehydrate the cement so that it cannot be pumped.

74

Concentric Hole Enlargement

The following operating parameters will serve as a guideline for all Reamaster jobs: 1. Smallest jet to be used in system is 1232 in. If possible, the lowest jet in system should be the largest. A variety of jets, including blanks, should be provided for all components. Diverging jets are required for cone pocket jets in the 9500 and smaller series Reamasters. The maximum flow per jet will be limited to 250 GPM. A float sub is always recommended when the BHA allows. 2. Flow velocities through the Reamaster will be limited to the following providing that solids control is in effect including desanders and desilters.

Reamaster Operating Parameters

Upper body or bench jets should be used to divert sufficient flow to achieve acceptable main bore velocities. 3. Lateral force on cutters derived from BHA analysis will be maintained below the following:

100 ft/sec. < 12 lb/gal. mud 75 ft/sec. > 12 lb/gal. mud

Reamaster Series
5750 7200 8250 9500 11750 16000

PDC Cutters (lb.)

1,000 1,000 1,500 1,500 2,000 2,000

Milled Tooth/TCI (lb.)

500 500 750 750 1,000 1,250

Note: The lateral force exerted on the cutters should always be minimized if possible through BHA analysis.

Concentric Hole Enlargement

75

4. Although formation characteristics will normally determine the appropriate RPM, the following is to be used as a guideline:

Underreamed Dia. (in.)

978 12 4
1

PDC Dia. (mm) 9

140 130 110 n/a n/a n/a

13 Recommended RPM
160 155 130 110 95 75

16
n/a n/a n/a 130 110 85

Milled Tooth/TCI RPM

80 - 150 80 - 150 80 - 150 80 - 150 80 - 150 80 - 150

1434 17 2
1

20 26

5. Bottom hole temperatures in excess of 300F require the use of Viton packings. 6. BHA recommendations should be as follows: Underream only Undergauge stabilizer should be run above the underreamer at a distance to minimize lateral force at underreamer cutters. The assembly below the underreamer should be an undergauge bit or slick bullnose. Minimum diametral clearance for either bit or bullnose should be one inch in pilot hole. Any full-gauge assemblies will require BHA analysis to meet lateral force requirements. Drill and underream The BHA will be determined by BHA analysis for lateral force requirements and directional objectives. 7. Flow distribution and pressure drop should be maintained on the following guidelines based on 12 lb/gal. mud:

Pilot Hole (in.)

61 2 9 7 8 105 8 121 4 143 4 171 2

Underreamed (in.)
9 7 8 121 4 143 4 171 2 20 26

Underream Only GPM

340 430 520 600 750 1,050

Drill and Underream GPM

n/a 600 740 900 1,000 1,300

psi
400 475 550 600 700 850

psi
n/a 525 600 700 850 1,000

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Concentric Hole Enlargement

Flow distribution between underreamer and bit/bullnose should be based upon application as follows: Underream only Minimum of 65 degrees of total flow rate should exit the Reamaster underreamer. Drill and underream Minimum of 20 degrees of the total flow rate should be directed to the bit. The balance of the flow rate should be divided between the bit and underreamer based on the area of formation removed by each. 8. Hydraulic horsepower per square in. should be maintained at the following: Underream only - 1.3 hhp/in.2 for underreamer - .5 for bit or bullnose Drill and underream - 1.3 hhp/in.2 for underreamer - 1.0 hhp/in.2 for bit 9. Effective weight-on-bit should be determined by allowable torque available based on the limitations of drillstring components. Maximum PDC weight is based on the number of PDC inserts that actually contact the underreamed bench area excluding redundant gauge cutters.

Reamaster Series
5750 7200 8250 9500 11750 16000

PDC Dia. (mm) 9

600 600 600 n/a n/a n/a

13 Max. Wt./PDC (lb.)

500 500 500 500 500 500

16
n/a n/a n/a 400 400 400

Max. Wt. Milled Tooth/TCI (lb.)

15,000 25,000 30,000 35,000 50,000 60,000

Concentric Hole Enlargement

77

Reamaster Underreaming Guidelines

The tool is normally run above the bit or bullnose. However, it can also be run in the drill collars string, up to 90 ft. above the bit. 1. Lower the tool into the hole until it reaches the top of the section to be enlarged. Take care when running in the hole, as surge pressures can start opening the arms, which may damage the casing. 2. Rotate the tool slowly (30 to 50 RPM) after reaching the desired shoulder cut-out depth. 3. While rotating the drillstring, start pumps and establish flow. 4. Gradually increase flow rate and RPM until desired operating parameters are reached.

Cutting the Shoulder

1. After correct pump pressure is reached, rotate the tool at 80 to 150 RPM maximum. Mark the kelly for three feet and drill off slowly. Rotate for five to ten minutes. 2. Disengage rotary table and pick back up while pump is still on. 3. Cutter arms should be fully open now. To make quite sure, repeat the above steps. When you reach the shoulder, you should start taking weight, indicating that you have a shoulder.

Underreaming

With the arms in the full open position the pilot hole can be underreamed. Maintain constant drilling weight. A good rule of thumb is 1,500 to 2,000 lb/in. of body diameter. Example: 12,375 to 16,500 lb. for a 81 4 in. tool. Reduce table speed to 80 RPM and proceed as follows: Allow drum to creep. Do not drill off. Establish a constant ROP and proceed. Do not spud tool. Pull at the first sign of dulling (look for the same signs as on a dull rock bit). Running time will depend on formation and cutter type. When a hard streak layer of formation is encountered, reduce speed and add weight in order to maximize penetration rate.

78

Concentric Hole Enlargement

Adding a Connection

1. After adding a connection, lower the kelly bushing so that it is barely in the table, and engage the rotary at slow speed. 2. Apply pump pressure. 3. Disengage rotary and lower tool to shoulder. 4. Set down on shoulder and apply weight to check if cutter arms have reopened. 5. Pick back up about two feet, engage rotary, bring to operating RPM and continue underreaming.

Tripping Out of the Hole

Pick up a few feet and turn pumps off. Allow five to ten minute rotations before coming out of the hole or into the casing shoe. Always pull into the casing slowly. Be sure hydrostatic head in the drillstring is allowed to equalize before pulling into the casing; otherwise, forces of the fluid column may expand cutter arms during entry. 1. Unscrew the hinge pin retaining screw and remove the washer and cap. 2. With snap ring pliers, remove the bail and slide the seat out of the hinge pin hole. 3. Using the long bolt supplied in the tool kit, pull the hinge pin out of the tool. 4. Slide the arm set out of the tool. 5. Break out the top sub and remove it from the tool. If a bit sub, bit or bullnose is made up to the tool, remove it also. 6. Break out the connection between the upper body and lower body. CAUTION: When breaking out this connection special care should be taken to keep the bodies perfectly aligned. Otherwise, severe damage caused by galling could occur. It is advisable to stand the tool in the vertical position to unscrew the connection. (On 16000 Reamaster, DO NOT torque on the sleeve. Remove the upper body to expose the inside of the tool. Remove the sleeve at this time.)

Reamaster Disassembly

Concentric Hole Enlargement

79

7. Using the small screw supplied in the tool kit, remove the two guide pins. 8. Slide the piston bore sleeve out of the lower body. 9. Insert the piston assembly tool, found in the tool kit, into the slot on top of the piston and hold in place with a bar. 10. Unscrew the cam and slide it out of the piston bore sleeve on 16000 Reamaster. Remove the floating seal cartridge at this time. CAUTION: DO NOT vise on the thin wall of the piston bore sleeve. 11. Remove the piston assembly tool and slide the piston and spring out of the piston bore sleeve. 12. Unscrew the arm stop retaining screw and remove the arm stops and washers. 13. Unscrew the orifice retainer and remove the orifices and O-rings. Remove and discard all O-rings, packings and screws used in the tool. Thoroughly clean all parts and check for damage. Replace parts if necessary.

XTU Underreamer Make-up Torque Specifications Upper Body to Lower Body Tool Series
5750 7200 8250 9500 11750 16000

Make-up Torque (ft/lb.)

10,500 33,000 43,000 63,000 88,000 88,000

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Concentric Hole Enlargement

Reamaster Components

Top sub

Upper body

Piston bore sleeve

Piston Guide pin Spring

Arm stop

Cam Hinge pin Cutter arm

Lower body

Concentric Hole Enlargement

81

Reamaster Assembly

When the tool is assembled all parts should be thoroughly lubricated. Any light grease is adequate. 1. Install packings on piston. Make sure the packings are installed facing upward. 2. Slide the spring and the piston into the piston bore sleeve. 3. Install the O-rings on the piston bore sleeve. (On 16000 Reamaster install the O-ring onto the floating seal cartridge and slide it onto the piston bore and sleeve at this time. Make sure the holes in the floating seal cartridge are aligned with the holes in the piston bore sleeve.) 4. Slide the cam through the lower end of the piston bore sleeve and screw it into the piston. To prevent the piston from turning during tightening, install the piston assembly tool into the piston and retain it with a bar. CAUTION: DO NOT vise on the thin wall of the piston bore sleeve. 5. When the cam is tight, remove the piston assembly tool. Continue to turn the cam until its slots are aligned with the holes in the piston bore sleeve. 6. Next, slide the piston bore sleeve into the lower body. Align the holes in the piston bore sleeve with the holes in the lower body and install the two guide pins. 7. Install the O-rings onto the lower body. (On 16000 Reamaster slide the sleeve onto the lower body and install the O-ring into the upper body at this time.) 8. Slide the upper body over the piston bore sleeve and down onto the lower body. Make-up the connection between the lower body and the upper body. CAUTION: When making up this connection special care should be taken to keep the bodies perfectly aligned. Otherwise, severe damage caused by galling could occur. It is advisable to stand the tool in the vertical position while installing the upper body. (On 16000 Reamaster DO NOT torque on the sleeve.) 9. Install the O-rings, orifices and orifice retainers into the lower body. 10. Put the arm stops in place and install the washers and screws to hold them in place. NOTE: Hold the arm stops against the top of the slots in the lower body to ensure adequate clearance for the arm set. 11. Slide the arm set into the tool, one arm assembly in each side. 12. Slide the hinge pin into the tool and through the two arm assemblies. 13. Install the hinge pin retainer seat, bail and pin. Make sure the gap in the bail straddles the hinge pin retainer pin. 14. Install the cap, washer and screw and tighten down.

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Concentric Hole Enlargement

NOTE: Make sure the arm assemblies swing freely before continuing. 15. Pull both arm assemblies out to the fully extended position and slide the proper sized ring gauge over the cutters to ensure proper opening size.

Reamaster Underreamer (XTU) Specifications Tool Opening Dia. Pilot Hole Body/ Fishing Neck Overall Top Pin/ Wt. (lb.) Series Size Coll. Length Dia. Length Bottom Dia. Box Conn. API Reg.
5750 812, 9 7200 9 8, 11, 11 4, 1214
7 3

578 - 612 7 2 - 11
1

534 7 4
1

18 18 18 24 20 20

434 5 4
3

90 99 123 136 130 140

312 4 2
1

500 700 900 1,100 1,700 3,200

8250 978, 1058, 11, 1214, 1312 9500 1214, 1312, 15, 16 11750 14, 15, 16, 1712 16000 20, 22, 24, 26

812 - 978 978 - 1214 1214 - 1412 1712 - 22

814 912 1134 165

534 85 85 10

412 658 658 858

Notes: 1. All dimensions are given in inches unless otherwise stated. 2. All weights are approximate. 3. Optional opening diameter available upon customer request. 4. Standard cutters are sealed-bearing milled tooth. TCI or PDC cutting structures must be specified. 5. The 5750 Series replaces the 5700, the 8250 replaces the 8200 and the 11750 replaces the 11700 Series. U.S. Patent Number: Underreamer 4,660,637 PDC Underreamer 4,431,065

Ordering Instructions: When ordering or requesting quotations on the Reamaster Underreamer (XTU), please specify: 1. Top and bottom connections 2. Fishing neck diameter 3. Expanded diameter 4. Size and weight of casing to be run through, if available 5. Bullnose ordered separately 6. Type of cutting structure (milled tooth, TCI or PDC)

Concentric Hole Enlargement

83

Reamaster Underreamer (XTU)

Fishing neck diameter Top pin connection

Fishing neck length

Body diameter

Overall length

Opening diameter Bottom box connection

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Concentric Hole Enlargement

Drilling-Type Underreamer (DTU)

DS, K2

DT

DG, C4

V2

Bearclaw PDC

F1 TCI

Cutter Options

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85

drillinG-type underreamer (dtu)

The Smith DTU will underream previously drilled pilot holes. A bottom box connection allows either a bit or bullnose to be run below the underreamer. The DTU may be used to drill and underream simultaneously. The tool design allows mud flow to the bit or bullnose. Flow can be divided depending upon application. Orifice jets can be selected in order to better utilize existing hydraulics. The jetting placement aids in keeping the cutters cool, and in annular lift of the cuttings. Selections include jetted bullnose and a jetted top sub in order to divert additional flow when necessary. These tools can be operated with water, mud, air, aerated mud or any other circulating medium. 1. Lower the tool into the hole until it reaches the top of the section to be enlarged. Take care when running in the hole, as surge pressures can start opening the arms, which may damage the casing. 2. Rotate the tool slowly (30 to 50 RPM) after reaching the desired shoulder cut-out depth. 3. While rotating the drillstring, start pumps and establish flow. 4. Gradually increase flow rate and RPM until desired operating parameters are reached.

Operating Guidelines

Cutting the Shoulder

1. After correct pump pressure is reached, rotate the tool at 80 to 150 RPM maximum. Mark the kelly for three ft. and drill off slowly. Rotate for five to ten minutes. 2. Disengage rotary table and pick back up while pump is still on. 3. Cutter arms should be fully open now. To make quite sure, repeat the above steps. When you reach the shoulder, you should start taking weight, indicating that you have a shoulder.

86

Concentric Hole Enlargement

Underreaming

With the arms in the full open position the pilot hole can be underreamed. Maintain constant drilling weight. A good rule of thumb is 1,000 lb/in. of body diameter: Example: 9,500 lb. for a 91 2 in. tool. Reduce table speed to 80 RPM and proceed as follows: Allow drum to creep. Do not drill off. Establish a constant ROP and proceed. Do not spud tool. Pull at the first sign of dulling (look for same signs as on a dull rock bit). Running time will depend on formation and cutter type. When a hard streak layer of formation is encountered, reduce speed and add weight in order to optimize the penetration rate.

Adding a Connection

1. After adding a connection, lower the kelly bushing so that it is barely in the table, and engage the rotary at slow speed. 2. Apply pump pressure. 3. Disengage rotary and lower tool to shoulder. 4. Set down on shoulder and apply weight to check if cutter arms have reopened. 5. Pick back up about two ft., engage rotary, bring to operating RPM and continue underreaming.

Tripping Out of the Hole

Pick up a few feet and turn pumps off. Allow five to ten minute rotations before coming out of the hole or into the casing shoe. Always pull into the casing slowly. Be sure hydrostatic head in the drillstring is allowed to equalize before pulling into the casing; otherwise, forces of the fluid column may expand cutter arms during entry. 1. Locate the DTU in the middle of the drill collars. 2. Diameters of the expanded arms must be equal to the bit size or larger. 3. Place a full gauge stabilizer 60 to 90 ft. above and another 60 to 90 ft. below the underreamer.

Underreaming Key Seats

Concentric Hole Enlargement

87

4. Slowly begin underreaming about 30 ft. above the key seat. 5. After underreaming the key seat, circulate for about five to ten minutes for tool clean-up. Stop circulation and wait a few minutes for pressure to equalize. This will allow the arms to collapse. 6. Slowly pull up. If you still have drag, repeat steps four and five. 1. Remove top sub. Break connections while tool is still in the rotary. 2. Remove hinge pin retaining screws, stop pins and hinge pins. 3. Slide cutter arm down and out. (DO NOT remove arm lugs unless necessary.) 4. Remove cam retainer. 5. Remove piston from body. Cam will slide off lower end of piston and may be removed through cone pockets. 6. Remove piston spring from body. 7. Remove bit or bullnose. 8. Remove snap ring from lower bore of tool body. 9. Remove piston stem packing housing from lower bore of tool body.

DTU Disassembly

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Concentric Hole Enlargement

Drilling-Type Underreamer (DTU) Components

Top sub

Body Piston stop

Piston packing Piston spring Lug retaining screws

Cutter arm hinge pin and retaining screw

Cutter arm lug Piston Cam and cam retainer Jet nozzles Piston housing Cutter arm

Cutter arm stop pin and retaining screw Piston stem Piston stem housing packing Piston housing retainer Bottom box connection (shown with bit sub and bit)

Concentric Hole Enlargement

89

Drilling-Type Underreamer (DTU) Assembly

1. Thoroughly lubricate all parts with a light grease. 2. Replace O-rings and the packing in the piston stem housing. Be sure the V-lips of the packing face the bottom of the tool. 3. Slide piston stem housing into lower bore of tool body. 4. Replace snap ring below piston stem housing. 5. Replace piston packing on piston head. Be sure V-lips face top of tool. 6. Place piston spring over piston stem and slide piston into body. 7. Reach through cone pocket and slide cam over lower end of piston stem. Move into position against shoulder. Be sure angle of cam faces down. 8. Replace cam retainer. 9. Replace cutter arms. 10. Replace hinge pins and stop pins. 11. Replace pin retaining screws. 12. Open and close tool with pneumatic air to check that all moving parts are functioning properly. 13. Ring gauge the arms in open position.

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Concentric Hole Enlargement

Drilling-Type Underreamer (DTU)

Body diameter

Fishing neck diameter

Top pin connection

Fishing neck length

Bottom box connection

Optional rock bit or bullnose

Standard opening diameter

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91

Drilling-Type Underreamer (DTU) Specifications Tool Standard Optional Body Series Opening Opening Dia. Dia. Dia.
3600 5700 7200* 8200* 9500* 11700* 15000* 17000* 22000 6 83 4 11 14 15 171 2 171 2 - 26 32 36 51 2 - 6 7 - 83 4 9 - 11 10 - 14 35 8 53 4 71 4 81 4

Collapsed Dia.
35 8 6 71 2 81 4 101 4 113 4 143 4 17 22

Through Casing Dia. x wt. (lb/ft.)

41 2 x 15 7 x 38 85 8 x 40 95 8 x 53 113 4 x 71 133 8 x 92 16 x 75 185 8 x 78 241 2 x 113

12 - 15 143 4 - 20 171 2 - 26 24 - 32 28 - 36

91 2 113 4 143 4 17 22

Drilling-Type Underreamer (DTU) Specifications (continued) Tool Fishing Neck Fishing Neck Overall Top Pin Conn. Series Length Dia. Length API Reg.
3600 5700 7200* 8200* 9500* 11700* 15000* 17000* 22000 8 18 18 18 18 20 20 20 20 33 8 43 4 53 4 53 4 or 8 8 8 8 or 9 9 or 10 9 or 10 35 70 74 79 82 96 97 87 100 23 8 31 2 41 8 41 2 or 65 8 65 8 65 8 65 8 or 75 8 75 8 or 85 8 75 8 or 85 8

Wt. (lb.)
170 360 770 900 1,150 1,670 2,800 3,000 4,400

* Available with PDC Bearclaw cutters. Notes: 1. All dimensions are given in inches unless otherwise stated. 2. All weights are approximate. 3. Optional opening diameter available upon customer request. 4. Standard cutters are open bearing milled tooth. TCI or PDC Bearclaw cutting structures must be specified.

Ordering Instructions: When ordering or requesting quotations on the DTU, please specify: 1. Tool series 2. Top and bottom connections 3. Fishing neck diameter 4. Opening diameter 5. Size and weight of casing to be run through, if available 6. Bullnose or bits are ordered separately 7. Type of cutting structure (milled tooth, TCI or PDC)

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Concentric Hole Enlargement

Rock-Type Underreamer (RTU)

DS, K2

DT

DG, C4

V2

Bearclaw PDC

F1 TCI

Cutter Options

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93

rock-type underreamer (rtu)

The Smith RTU is a rugged three-cone underreamer. The large cones enable the RTU to underream a hole nearly twice its own body diameter. A complete range of cone availability ensures proper cutter to formation selection. A variety of orifice sizes enable the operator to tailor performance to hydraulics and other conditions at the rig. The tool can be serviced on location, and the cutter arms can be quickly and easily changed on the rig floor. The tool design allows full volume circulation at all times. The RTUs can be operated with water, mud, air, aerated mud, foam or any other circulating medium.

Operating Guidelines

1. Lower the tool into the hole until it reaches the top of the section to be enlarged. Take care when running in the hole, as surge pressures can start opening the arms, which may damage the casing. 2. Rotate the tool slowly (30 to 50 RPM) after reaching the desired shoulder cut-out depth. 3. While rotating the drillstring, start pumps and establish flow. 4. Gradually increase flow rate and RPM until desired operating parameters are reached.

Cutting the Shoulder

1. After correct pump pressure is reached, rotate the tool at 80 to 150 RPM maximum. Mark the kelly for three ft. and drill off slowly. Rotate for five to ten minutes. 2. Disengage rotary table and pick back up while pump is still on. 3. Cutter arms should be fully open now. To make quite sure, repeat the above steps. When you reach the shoulder, you should start taking weight, indicating that you have a shoulder.

Flo-Tel Equipped Rock-Type Underreamer (RTU)

Rotate the tool at 80 to 150 RPM with maximum pump pressure. Flo-Tel equipped underreamers indicate when the cutter arms are fully extended and the tool is underreaming at full gauge. Flo-Tel effectively substitutes for a larger orifice when the cutter arms are extended. Pressure on the mud pump gauge then drops by about 200 to 250 psi or the number of pump strokes increases. These clear signals from Flo-Tel assure that the hole has the right diameter every time, eliminating second trips. Flo-Tel is especially recommended for cutting shoulder in hard formations.

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Underreaming the Interval

Having cut the shoulder, add weight. A good rule of thumb is 1,000 lb. for each in. of body diameter. Example: 6,000 lb. for a six in. tool. Reduce speed to 80 RPM and proceed with underreaming. Allow drum to creep. Do not drill off. DO NOT allow tool to penetrate faster then 100 ft/hr. or the hole may not open to the desired drift gauge. DO NOT spud the tool. Pull the underreamer at first sign of dulling (look for same signs as on a dull rock bit). Running time will depend on formation and cutter type. In a sidetracking operation, remove the cement ring with an underreamer whose cutter opening is slightly larger than the original hole. When you encounter a hard streak formation layer, reduce table speed and add weight.

Adding a Connection

1. After adding a connection, lower the kelly bushing so that it is barely in the table, and engage the rotary at slow speed. 2. Apply pump pressure for normal underreaming operations. 3. Disengage table and lower tool to shoulder. 4. Set down on shoulder and apply weight to check whether cutter arms have reopened. 5. Pick back up about two ft., engage table, bring to operating RPM and continue underreaming. Follow the above procedure after each connection.

Tripping Out of the Hole

Pick up a few feet and turn pump off. Allow five to ten minute rotations before coming out of the hole or into the casing. Always pull into the casing shoe slowly. Be sure hydrostatic head in the drillstring is allowed to equalize before pulling into the casing; otherwise, forces of the fluid column may expand cutter arms during entry.

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1. Remove top sub. Break connection while tool is still in the drillstring. 2. Remove Flo-Tel retainer, if applicable. 3. The Flo-Tel unit may now be withdrawn from the body. 4. Remove pin retaining screws. Remove arm stop pins and arm hinge pins. 5. Remove cutter arms. Do not remove cutter arm lugs. 6. Use wrenches furnished with tool kit to remove cam locknut and cam. 7. Withdraw piston and spring from the body.

Rock-Type Underreamer (RTU) Disassembly

Rock-Type Underreamer (RTU) Assembly

1. Thoroughly lubricate all parts with a light grease. 2. Assemble piston: Replace piston packing with V-lips facing top end of tool. Replace orifice, orifice O-ring and orifice retainer. 3. Place spring over piston stem and slide piston assembly into body. 4. Depress piston to full open position. 5. Insert cam through cone pockets, and assemble cam on the piston with cam wrench furnished in tool kit. 6. Install the cam locknut firmly. 7. Install arms. Use new hinge pins and retaining screws. 8. Open and close tool with pneumatic air to check that all moving parts are functioning properly. 9. Ring gauge the arms in open position.

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Rock-Type Underreamer (RTU) Components

Top sub

Body

Piston packing Piston Spring Arm lug Arm lug retaining screw Arm hinge pin and retaining screw Arm stop pin and retaining screw

Piston stem

Cam

Orifice O-ring and assembly

Cutter arm

Spade

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Rock-Type Underreamer (RTU) Components

Fishing neck diameter Top pin connection

Fishing neck length

Body diameter

Standard opening diameter

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Rock-Type Underreamer (RTU) Specifications Tool Series Standard Optional Opening Dia. Opening Dia.
3600 4500 5700 5800 6000 6100 6200 7200* 8200* 9500* 11700* 15000 LP* 22000 6 61 2, 81 2 11 11 12 12 12 14 16 171 2 171 2 26 32 - 40 43 4 - 61 2 6-9 8 - 11 8 - 11 11 - 12 11 - 12 11 - 13 9 - 14 10 - 16 13 - 18 143 4 - 22 171 2 - 30 32 - 40

35 8 41 2 53 4 578 6 61 8 61 4 71 4 81 4 91 2 113 4 143 4 22

Body Collapsed Through Casing Dia. Dia. Dia. x wt. (lb/ft.)

33 4 45 8 578 578 61 8 61 8 61 4 73 8 83 8 93 4 121 4 143 4 22 41 2 x 15 51 2 x 20 7 x 38 65 8 x 20 7 x 26 7 x 20 7 x 17 85 8 x 40 95 8 x 47 103 4 x 45 133 8 x 68 16 x 75 241 2 x 113

Rock-Type Underreamer (RTU) Specifications (continued) Tool Series Fishing Neck Fishing Overall Top Pin Conn. Length Neck Dia. Length API Reg.
3600 4500 5700 5800 6000 6100 6200 7200* 8200* 9500* 11700* 15000 LP* 22000 8 18 18 18 18 18 18 18 18 18 20 20 20 33 8 41 8 43 4 43 4 43 4 43 4 43 4 53 4 3 4 or 8 5 8 8 8 or 9 9 or 10 261 2 67 761 2 761 2 781 2 781 2 781 2 86 89 91 91 97 1241 4 23 8 278 31 2 31 2 31 2 31 2 31 2 41 2 41 2 or 65 8 65 8 65 8 65 8 or 75 8 75 8 or 85 8

Wt. (lb.)
175 235 380 380 380 380 380 775 920 1,160 1,670 2,800 5,900

* Available with PDC Bearclaw cutters. Notes: 1. All dimensions are given in inches unless otherwise stated. 2. All weights are approximate. 3. Optional opening diameter available upon customer request. 4. Standard API regular pin connections. Others available upon customer request.

Ordering Instructions: When ordering or requesting quotations on the RTU, please specify: 1. Tool series 2. Top and bottom connections 3. Fishing neck diameter 4. Opening diameter 5. Size and weight of casing to be run through, if available 6. Bullnose or bits ordered separately 7. Type of cutting structure (milled tooth, TCI or PDC)

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SPX/Drag-Type Underreamer

Special meritorious engineering award for innovation and efficiency.

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spX/draG-type underreamer
SPX (PDC) cutters on the cutting edge of the drag tool provides the hardness and wear resistance of man-made polycrystalline diamond, backed by the strength and toughness of cemented tungsten carbide. These cutters shear through soft to medium-hard formations faster than conventional tools would, and require less tool weight. The tool features a special circulation jet nozzle which directs a portion of the flow out of each arm pocket. This action effectively cleans the cutting surfaces, improves removal of cuttings and dissipates frictional heat. Advantages of using the SPX/drag-type underreamer are: Increased penetration rate Increased on bottom time Reduced rig time due to faster penetration Reduced total cost per ft. Faster penetration through producing zones minimizes formation damage and hole stability problems Drag-type underreamers are used in poorly consolidated soft to medium formations where larger diameter intervals are required for gravel packing or cementing. Pilot holes can be enlarged up to three times body diameter in a single trip. These tools can be operated with water, mud, air, aerated mud, foam or any other circulating medium. Low-cost cutter arms and orifices can be replaced in the field. The arms of drag-type tools are dressed with long wearing cutting grade tungsten carbide.

Operating Instructions

Lower the tool into the hole until it reaches the top of the section to be enlarged. Take care when running in the hole, as surge pressures can start opening the arms, which may damage the casing. 1. Begin rotation at 40 to 60 RPM. 2. Turn on the mud pump; gradually increase flow rate 250 to 450 GPM. 3. Begin to apply weight at 3,000 lb. 4. Continue rotating the tool until the cutter arms are fully extended. Models with Flo-Tel will show a sudden drop in pump pressure or increase in pump strokes. 5. Mark the kelly for three ft. and drill off slowly. 6. After three ft. drill off, rotate the tool for five to ten minutes. 7. Disengage rotary and pick up while the pump is still on. 8. Cutter arms should be fully open now. To make sure, repeat the above steps. When you reach the shoulder, you should start taking weight. Adjust weight and speed for optimum ROP.

Cutting the Shoulder

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Flo-Tel Equipped SPX/Drag-Type Underreamer

Rotate the tool at 80 to 150 RPM with a maximum pump pressure. Flo-Tel equipped underreamers indicate when the cutter arms are fully extended and the tool is underreaming at full gauge. Flo-Tel effectively substitutes for a larger orifice when the cutter arms are extended. Pressure on the mud pump gauge then drops by about 200 to 250 psi or the number of pump stroke increases. These clear signals from Flo-Tel assure that the hole has the right diameter every time, eliminating second trips. Flo-Tel is especially recommended for cutting a shoulder in hard formations.

Underreaming the Interval

1. When the cutter arms are fully extended, apply weight. Begin with 3,000 lb. and increase up to 10,000 lb. 2. Continue rotating until completing the section of the hole or until a new joint of pipe has to be added to the drillstring.

Adding a Connection

1. After adding a connection, lower the kelly bushing so that it is barely in the table and engage the rotary at slow speed. 2. Apply pump pressure. 3. Disengage rotary and lower tool to shoulder. 4. Set down on shoulder and apply weight to check whether cutter arms have reopened. 5. Pick back up about two ft., engage rotary, bring to operating RPM and continue underreaming.

Tripping Out of the Hole

Pick up a few feet and turn pumps off. Allow five to ten minute rotations before coming out of the hole or into the casing shoe. Always pull into the casing shoe slowly. Be sure hydrostatic head in the drillstring is allowed to equalize before pulling into the casing; otherwise, forces of the fluid column may expand cutter arms during entry.

SPX/Drag-Type Underreamer Disassembly

1. Remove Flo-Tel retaining ring and Flo-Tel assembly, if applicable. 2. Push piston down to open cutter arms. 3. Remove hinge pin retaining screws and hinge pins. 4. Remove arms. 5. Remove arm stops. 6. Release piston and remove from tool. 7. Remove piston tube retaining ring, piston head, O-rings and packing.

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SPX/Drag-Type Underreamer Components

Top sub

Body

Piston stem retaining screw O-ring Piston stem Arm stop

Flo-Tel assembly Piston head Piston packing Spring Arm stop retaining screws

Three-way jet nozzle

Cutter arm Arm hinge pin and retaining screw

Spade

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1. Thoroughly lubricate all parts with light grease. 2. Assemble piston: Replace piston packing with V-lips, facing up. Replace orifice, packing, washer and retainer. 3. Place spring over piston stem and slide assembly into body. 4. Push piston down to full open position. 5. Install arms in open position using new hinge pins and retaining screws. 6. Open and close tool with pneumatic air to check that all moving parts are functioning properly. 7. Ring gauge the arms in open position.

SPX/Drag-Type Underreamer Assembly

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SPX/Drag-Type Underreamer

Fishing neck diameter

Fishing neck length

Body diameter Expanded diameter

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SPX/Drag-Type Underreamer Specifications

Tool Series Body Min. Recom. Dia. Pilot Hole Dia. 33 4 43 4 5 6 75 8 81 2 978 121 4 41 2 Std. Expanded Dia. Fishing Neck SPX Tungsten Length Dia. Carbide N/A 9 8 33 8 1 3 6 2, 6 4, Upon 18 41 4 812 request Upon 12 18 41 8 request 1 1 7 2, 8, 8 2, 16 18 43 4 12, 13 10, 1214, 13, 14, 15, 22 18 53 4 16 10, 1214, 53 4, 14, 15, 16, 23 18 8 17 1214, 1712 28 18 8 Upon 36 18 8, 9 request Overall Top Pin Conn. API Length 261 2 23 8 Reg. 69 67 70 78 31 2 IF Wt. (lb.) 185 230 250 350 750

3600 33 8 4500

4700 43 4 5700 53 4 7200 71 4 8200 81 4 9500 91 2 11700 113 4

278 Reg. 31 2 Reg. 41 2 Reg. 41 2 or 65 8 Reg. 65 8 Reg. 65 8 or 75 8 Reg.

78 78 86

900 1,100 1,400

Notes: 1. All dimensions are given in inches unless otherwise stated. 2. All weights are approximate. 3. Other expanded diameters available upon request. 4. Orifices other than standard available upon request. 5. Standard API pin connections. Others available upon request.

Ordering Instructions: When ordering or requesting quotations on the SPX/Drag-Type Underreamer, please specify: 1. Tool series 2. Top and bottom connections 3. Fishing neck diameter 4. Opening diameter 5. Size and weight of casing to be run through, if available 6. Bullnose or bits are ordered separately 7. Type of cutting structure (milled tooth, TCI or PDC)

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Gauge Diameter Tolerances Underreamers Size

6 - 9 (Incl.) 91 2 - 13 (Incl.) 14 - 18 (Incl.) 20 - 30 (Incl.)

Tolerance
+ 1 16 - 0 + 3 32 - 0 + 1 8 - 0 + 3 16 - 0

Notes: 1. All dimensions are given in inches unless otherwise stated. 2. The above gauge diameters apply to a set of arms in open position when assembled in a tool. 3. The specification covers arm sets used on all RTU, DTU, Drag and XTU underreamers. 4. The specification applies to milled tooth, TCI and PDC cutting structures.

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rhino reamer system

The Rhino Reamer System is Smith Services latest technology endeavor that will enable an operator to enlarge the wellbore below a restriction. The most frequently encountered restrictions are the drift diameter of the casing and the size of the wellhead. Both limit the maximum outside diameter (OD) of the tools that can pass through. The Rhino Reamer System is capable of drilling the float equipment and continuing onward to begin hole enlargement. Hole enlargement takes place at some point below the surface. Since the tool has to first pass through the restricted bore, it incorporates expandable cutter sets which stay collapsed while the tool is run into wellbore. Once the tool has cleared the casing and wellhead, the cutter sets expand into the formation by utilizing the differential pressure of the drilling fluid or pneumatic medium. The Rhino Reamer utilizes a patented Z-Drive actuation system that traverses the cutter sets to a pre-selected diameter, and then hydraulically clamps them into position. This eliminates cutter block movement and vibration, which improves PDC cutting structure life. The actuation system uses a parallel tongue and groove (Pocket Slip technology) profile machined on each side of the cutter block as well as in the tool body to guide and control cutter block deployment. The Z-Drive and cutter block system eliminates conventional hinge pins and long cutter sets limited to only one opening diameter. The Rhino Reamer uses a threaded sleeve inside the bore of the tool to adjust opening diameter. Limiting the distance the cutter block can traverse dictates the opening diameter within the designed range.

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The tool is dependent on hydraulic pressure to both deploy the cutter sets and to cool and clean the cutting structure. Jet nozzles are strategically placed adjacent to each cutter block and actually travel with the cutter sets to ensure optimum cleaning at any opening diameter. The jet nozzles open only when the cutter sets are fully actuated, providing an indication at surface that the Rhino Reamer is open. Once the hole is enlarged to the desired depth, the pumps are turned off allowing the cutter sets to collapse into the body. The tool is then pulled out of the hole through the restricted section.

Rhino Reamer System

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Rhino Reamer Specifications

Tool Series Min. Pilot Hole Size (in.) 3M\, 6 6Z\v 8C\, 9Z\x 10Z\x 12 12Z\, 14C\v 16Z\x 18Z\x Hole Opening Size (in.) 4 - 4Z\x 6Z\x - 7Z\x 7 - 8Z\v 9Z\v - 10 10Z\x - 11C\v 11Z\v - 12Z\v 13 - 14C\v 13Z\v - 15 15C\v - 17Z\x 17Z\x - 20 19Z\x - 22 Max. Body OD (in.) 3Z\x 5C\v 6Z\, 8 9Z\v 10 11B\, 11C\v 14Z\v 16 16 Min. Collapsed Dia. (in.) 3Z\x 5C\v 6Z\, 8 9Z\v 10 11B\, 11C\v 14Z\v 16 18 Std. Fishing Neck Dia. (in.) 3C\, 4C\v 4C\v 6Z\x 6Z\x 8Z\v 8Z\v, 9Z\x 8Z\v, 9Z\x 9Z\x 9Z\x 9Z\x Fishing Neck Length Min. (in.) 6Z\x 18 18 18 18 18 18 18 18 18 18 Max. Thru Flow (GPM) 140 350 350 750 750 1,200 1,200 2,000 2,000 2,000 2,000

3500 5750 6125 8000 9250 10000 11625 11750 14250 16000 16000

Pre-job Planning and Preparation

Pre-job planning and preparation is vital to the successful deployment of the Rhino Reamer. Accurate hydraulic requirements of the tools above and below the Rhino Reamer are critical.

Mechanical Analysis

Perform a mechanical analysis on all Rhino Reamer bottom hole assemblies to optimize the tool and stabilizer placement.

Pre-run Checklist

Prior to running the equipment, perform the pre-run checklist. Review and evaluate job objectives with the on-site customer representative. Verify that all necessary equipment has been delivered to the location. Check and verify tool joint connections. Inspect all equipment for possible damage during shipment. Inform the customer immediately of shortages or damage. Caliper tool, gauge drop ball (if required), and record all equipment dimensions that will be used on the job. Record on strap sheet. Verify the pipe tally with drilling personnel and/or customer representative to determine the starting depth for tool operation.

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Review, verify and record hydraulic requirements in order to achieve optimum performance.

General Procedure for Making up the Rhino Reamer

Clean and grease the API pin and box connections on the mating BHA components. If applicable, set the BHA components to be run below the tool in the rotary table. Use lifting sub and elevators to pick up Rhino Reamer tool and lower onto lower BHA. Make-up to the specified torque listed in Table 1.

Table 1 Make-up Torque of Top and Bottom Subs to Rhino Reamer Body
Tool Series Description Make-up Torque

5625, 5750, 6125 8000 9250 10000, 10375 11625 11750, 14250, 16000

4Z\x Reg. Box x 4Z\x Reg. Box 6B\, Reg. Box x 6B\, Reg. Box 6B\, Reg. Box x 6B\, Reg. Box T-38 Box x T-38 Box 6B\, IF Box x 6B\, IF Box T-20 Box x T-20 Box

13,000 ft/lb. 45,600 ft/lb. 56,200 ft/lb. 66,000 ft/lb. 97,800 ft/lb. 107,600 ft/lb.

CAUTION: Never place the tongs over the cutter sets. See figure 3 for tong placement.

Figure 3 Tong Placement

Place tongs here

Place tongs here

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Rhino Reamer Make-up and Surface Test Procedure for Lockout Mechanism and Hole Enlargement While Drilling Only

Pick up the pre-made up rotary BHA components to be tested, make-up the drill bit and lower it in the hole. DO NOT make-up the Rhino Reamer. Pick up and make-up a crossover sub and/or pup joint and make-up to the top drive. Test the rotary steerable system and/or Measuring While Drilling (MWD) assembly per manufacturer specifications. Lay down the crossover sub and/or pup joint. Pick up the Rhino Reamer assembly. Pick up and make-up a crossover sub and/or pup joint and make-up to the top drive. Slack off until the Rhino Reamer cutter sets are below the rotary table. Bring the mud pumps online and gradually increase the flow rate to the pre-established value as specified in the hydraulic analysis for drill out (H3). Verify that the cutter sets have not activated. From the time the Rhino Reamer goes through the rotary table until it reaches bottom, care must be taken when tripping in the hole. Care should also be taken when running through diverters, blowout preventers (BOP), wellheads and casing shoes.

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Drilling the Casing Shoe Track

Lower the BHA into the hole until it reaches the top of the cement plug. Tag the cement plug with the drill bit and pick up approximately ten ft. off bottom. Start pumps and establish flow to the drill out flow rate as specified in the hydraulic analysis (HB3 or H3) and then rotate the tool slowly (30 to 50 RPM). Increase RPM until desired operating parameters are reached. Ream and wash down to the top of the cement. Drill the casing shoe track with the customer specified drill out flow rate (HB3 or H3). Back ream and re-ream every 30 ft. of the casing shoe track drilled in an attempt to prevent the hole from packing off. After the casing shoe has been drilled out and a successful Formation Integrity Test is taken, it is recommended to drill ahead with the Rhino Reamer closed until the tool is 20 to 30 ft. below the casing shoe while noting torque, WOB and ROP required to drill. CAUTION: Be aware that while drilling ahead with the Rhino Reamer closed over an extended period of time, cuttings can accumulate in the upper portion of the tool, possibly inhibiting full opening diameter. Lower the BHA into the hole until the Rhino Reamer is ten to 15 ft. below the casing shoe. Bring up pumps to shear out flow rate as established by the hydraulic analysis (HB4). Shut the pumps off. The cutter blocks should be activated now. If not sure, repeat the activation steps using the shear out flow rate (HB4). If unable to activate the cutter sets using the shear out flow rate (HB4), drop the ball in the drill pipe. Note: When using the ball drop mechanism, the Smith Services operator is required to gauge the drop ball to ensure that it will pass through all drill string components, i.e. float valve, PBL sub, etc. In order to drop a ball and activate the tool the Rhino Reamer must be located above the MWD. Slowly pump the ball down the drill string until the ball seats in the catch. Increase the pump pressure to shear the shear pins and activate the cutter sets.

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A decrease in pump pressure should be seen at the surface to signal that the cutter blocks are activated. Once the tool function is verified, proceed with cutout. Note: A pull test at the casing shoe can be performed to verify that the cutters blocks are activated.

Cutting the Shoulder

Lower the BHA into the hole until the Rhino Reamer is ten to 15 ft. below the casing shoe. Rotate the tool slowly (30 to 50 RPM) and very slowly bring pumps up to the appropriate drill ahead flow rate (H1 or HB1) to perform the cut-out. Rotate while working the tool up and down approximately five to ten ft. until a cut-out is established. Note: The time required to initiate a cut-out will vary depending on formation type and properties. Establish the cut-out while noting weight and torque. Once the cut-out is complete, with the pumps on and the rotary off, slowly lower the Rhino Reamer towards the bottom of the cut-out. Weight should be seen on the indicator at the bottom of the cutout bench, verifying cutter block activation. Note: The bit should be off bottom at this time to ensure that the weight noted is at the Rhino Reamer cutter blocks. Drill off slowly while noting weight and torque.

Hole Enlargement

With the cutter blocks activated, the pilot hole can be enlarged. Maintain constant drilling weight.

Tripping Out of the Hole

Perform a pull test at the casing shoe to verify that the tool is functioning properly. Take care while pulling into the casing and other restrictions. At the surface, thoroughly flush the inside of the tool and the cutter pockets with water. The following operating parameters will serve as a guideline for all Rhino Reamer jobs.

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conventional, drill and ream, rotary steerable systems

BHA recommendations should be as follows: Ream only An under gauge stabilizer should be run above the underreamer at a distance to minimize lateral force at the underreamer cutters. The assembly below the underreamer should be an under gauge bit or slick bullnose. Minimum diameter clearance for either bit or bullnose should be one inch in pilot hole. Any full-gauge assemblies will require BHA analysis to meet lateral force requirements. Hole Enlargement While Drilling (HEWD) - The BHA will be determined by mechanical analysis for lateral force requirements and directional objectives. Flow distribution between reamer and bit/bullnose should be based upon application as follows: Ream only Minimum of 65 percent of the total flow rate should exit the Rhino Reamer. HEWD Minimum of 20 percent of the total flow rate should be directed to the bit. The balance of the flow rate should be divided between the bit and Rhino Reamer, based on the area of formation removed by each.

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Table 2 Recommended HEWD Flow Distribution

Tool Series Min. Pilot Hole Size (in.) Opening Dia. (in.) % Flow to Bit % Flow to Rhino

5625 5750 6125 8000 9250 10000 10375 11625 11750 14250 16000

53/4 53/4 6 6 61/4 61/4 83/8 83/8 91/2 91/2 101/2 101/2 105/8 105/8 121/8 121/8 121/4 121/4 143/4 143/4 161/2 161/2

61/2 7 61/2 71/2 63/4 81/4 91/4 10 10 113/4 111/4 121/4 113/4 131/2 13 143/4 131/4 15 153/4 171/2 171/2 20

88 71 88 71 85 66 85 76 90 73 90 76 87 71 90 74 87 73 90 76 90 75

12 29 12 29 15 34 15 24 10 27 10 23 13 29 10 26 13 27 10 24 10 25

Note: The rig capacity and job specifications will dictate the actual hydraulics available to the tool.

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The optimal hydraulic horsepower per square in. should be maintained at the following: Ream only 1.3 hhp/in. for reamer 0.5 hhp/in. for bit or bullnose HEWD 1.3 hhp/in. for reamer 1.0 hhp/in. for bit

Operating Parameters

Effective weight-on-bit (WOB) should be determined by allowable torque available based on the number of PDC inserts that actually contact the underreamed bench area excluding redundant gauge cutters. As the PDC cutters wear down, the wear flats generated will continuously absorb more of the applied weight and ROP will diminish. A gradual increase of weight will usually be necessary to re-establish the ROP. Generally an increase in WOB should be implemented before rotary speed, so the PDC cutters will attain a minimum depth of cut. For any occurrences of high torque and vibrations, adjustments in WOB and/or RPM should be considered to reduce the chances of high impact loading on the Rhino Reamer and other downhole components.

Maximum Flow Rate through the Rhino Reamer

Tool Series 5750 6125 350 466 5 -13 35 105 8000 9250 734 979 7 - 20 72 216 10000 10375 11625 1147 1530 7 - 24 141 423 11750 14250 2249 2999 7 - 24 141 423 16000

Max. through flow rate at 75 ft/ sec., GPM Max. through flow rate at 100 ft/sec., GPM Available nozzle sizes (ID) 1/32 in. Max. flow rate through each nozzle 75 ft/sec., GPM Max. flow rate through three nozzles 75 ft/sec., GPM

2249 2999 8 - 32 207 621

Note: The parameters stated above are recommended and actual drilling conditions may require alternate parameters.

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117

Bit Hydraulics
Hydraulic and mechanical energy are needed for efficient rock cutting and removal when drilling. The hydraulic energy is provided by the drilling medium or mud being pumped down the ID of the drillstring. The mechanical energy is supplied by the speed or RPM at which the string turns and the amount of weight applied to the bit. The weight-on-bit (WOB) controls the chip size and quantity of the cuttings. The RPM controls the fracture rate or ROP. The removal of these cuttings is both mechanical and hydraulic; the teeth of the bit being mechanical and the hydraulics of the orifice to lift the cuttings away from the bit and up the annulus. In order to increase the hydraulic energy necessary at the bit, select the correct orifice. Once the orifice is selected, consider other factors which will affect cutting removal. Particle slip velocity Mud properties (density, viscosity) Circulation rate (annular velocity) WOB Drillstring rotation (RPM) Pump pressure Formation type Once all these factors are taken into consideration we can proceed with our drilling objectives, confident we will have optimum performance from our mechanical and hydraulic energy available. The Flow of Fluid Under Pressure Most noted for his study of the effects of flowing fluid under pressure was Mr. Daniel Bernoulli. Bernoulli, an eighteenth century scientist, was a member of a famous European family of scientists and mathematicians. He devoted a good portion of his life to studying hydraulics and the flow of fluid under pressure. He is most famous for his theory or equation (Bernoullis Theorem): when a fluid is flowing under high pressure it has a slow velocity or slow traveling time. Once restricted down to a smaller diameter, the pressure is less and velocity is increased or the fluid travels much faster. For example, lets put some numbers to this to make it clearer. We are pumping 300 GPM through our drillstring and return flow is 300 GPM. In the larger diameter (our drillstring ID) lets say we have 1,000 psi pressure and a velocity, or traveling time, of 20 ft/sec. Once the fluid reaches the smaller diameter (orifice jet in bit), the psi pressure would drop to 800 psi and our velocity would exceed 100 ft/ sec. low pressure/high velocity. Thus, we have created a pressure drop or pressure differential of 200 psi (1,000 800 psi = 200 psi) at the orifice of the bit.

118

Hydraulics

Underreamer Hydraulics Having explained bit hydraulics and factors involved, let us move on to underreamer hydraulics. Smith underreamers are hydraulically actuated. The mud pumped down the string flows into the tools piston bore. The pressure then moves the piston (with attached cam) down the tool, mechanically actuating the cutter arms by contact on the cam ramp. These arms will stay open as long as the pumps are on; once shut off, the piston will retract due to the piston spring moving back into a free state. All underreamers can be actuated by a minimal amount of pneumatic pressure (65 psi shop air), but we recommend a minimum pressure differential of 350 to 650 psi to maintain the open position of the tool downhole. Note: This will be higher during Underreaming While Drilling (UWD) operations. In order to maintain the proper pressure differential or pressure drop we must select the correct orifice. (See example in this handbook on pages 126 through 129.) In addition to maintaining the tool open, we also rely on hydraulics in underreaming to cool and clean the cutters and lift the cutting up the annulus. So our orifice selection has to be very accurate. Problems can arise if the orifice jet is incorrect or we are pumping high flow rates (GPMs). In addition, if our mud has a high solid content, premature erosion or a washout can take place. This action can cause excessive tool damage and, due to the need to trip out of the hole, costly rig time. All Smith underreamers use 70 or 95 Series jets. The 70 Series is the jet model, a second number such as 1 2 or 16 (16 32) will be given to denote size. Based on all the same factors as we discussed in Bit Hydraulics (factors one through seven) we will be able to choose the necessary jets to keep the underreamer open, cool, clean the cutters, and lift the cuttings up the annulus, keeping our hole clean. If we attach a bit or bullnose to the bottom of our DTU, we must also take into consideration any extra jets which might change our pressure differential or pressure drop. So as you can see, underreamer hydraulics, like bit hydraulics, are very critical to the tool performance. In order to determine opening force of underreamer cutters against formation use the following chart and formula.

Hydraulics Hydraulic Tool Opening Force Piston Head Area (in.2) Tool Series
3600 4100 4500 4700 5500 5700 5800 6000 6100 6200 7200 8200 9200 9500 10500 11000 11700 15000 16000 17000 22000 50.266 50.266 50.266 50.266 30.680 50.266 50.266 38.485 38.485 30.680 18.665 19.635 30.680 50.266 38.485 30.680 18.655 18.655 12.566 12.566 12.566 12.566 12.566 12.566 19.635 18.665 9.621 19.635 18.665 18.665 9.621 12.566 7.069 8.296 12.566 12.566

119

DTU
3.142

RTU
3.142

Reamaster

Drag

PDC

Hydraulic tool opening force: Fh = PD Ap Where: Fh = Hydraulic opening force, lb. PD = Pressure drop across tool, psi Ap = Piston head area, in.2

120

Hydraulics

In order to select a flow that will not erode tool prematurely, opening force of underreamer cutters, use the following chart and formula: Maximum Hydraulic Tool Flow Rate Piston Bore TFA (in.2) Tool Series
3600 4100 4500 4700 5500 5700 5800 6100 6200 7200 8200 9200 9500 10500 11000 11700 15000 17000 22000 3.142 3.142 3.142 3.142 7.069 .785 1.624 1.624 3.143 .994 1.227 .785 3.143 .994 1.227 1.227 .442 .442 .442 .442 .442 .785 .785 1.485 2.406 .442 .442 .442 1.227 1.227 1.227 1.227 1.227 .442 .442 .442 .307 .442 .442 .785

DTU
.624

RTU
.624

Drag

K-Mill
.307 .442 .442

PDC

Maximum hydraulic tool flow rate: VAb GPMm = 0.32 Where: GPMm = Maximum flow rate, GPM V = Piston bore velocity, ft/sec. V = 150 all tools except 45 to 117 km V = 200, 45 to 117 km Ab = Area of piston bore, in.2 Notes: 1. Reamaster is not included since bore velocity depends on nozzle TFA. 2. Use a piston bore velocity of 150 ft/sec. to prevent erosion. 3. Values in bold under K-Mills may use 200 ft/sec. velocity due to anti-wash tubes.

Hydraulics The Reamaster velocity should not exceed 75 ft/sec., whereas velocity in the DTUs and RTUs should not exceed 150 ft/sec. In order to determine velocity through underreamers and minimize erosion, use the following equation. Piston Bore Velocity Vp = 0.32 GPM Ab

121

Where: Vp = Piston bore velocity, ft/sec. GPM = Flow rate Ab = Area of piston bore, in.2 In order to determine pressure drop across the underreamer piston use the following equation. Hydraulic Tool Pressure Loss PD = (MW) (GPM) 10,858 (TFA)2
2

Where: PD = Pressure drop across piston, psi MW = Mud weight, lb/gal. GPM = Pump volume through tool TFA = Total flow area of jet nozzles, in.2 The chart on the following page will determine the ratio of formation removed between the underreamer (or hole opener) vs. the previously drilled pilot hole. This chart can be used to determine the correct jet nozzle selection based on the percentage of formation removed between the two holes.

122

Hydraulics

Net Annular Area Removed with Underreamer or Hole Opener vs. Bit Pilot Hole
Bit Size Area in. in.2
41 8 43 4 57 8 67 8 61 8 61 4 61 2 63 4 77 8 83 8 81 2 83 4 91 2 9 7 8 10 5 8 117 8 121 4 131 2 143 4 171 2 207 8 227 8 247 8 267 8 287 8 13.36 17.72 27.11 28.27 29.47 30.68 33.18 35.79 48.71 55.09 56.75 60.13 70.88 76.59 88.64 95.03 117.86 143.14 170.87 240.53 314.16 380.13 452.39 530.93 615.75

Opening Dia. (in.) 6.50 7.87 8.50 9.00 9.87 11.00 12.25 13.00 13.50 14.75 16.00 17.50 20.00 33.18 48.71 56.75 63.62 76.59 95.03 117.86 132.73 143.14 170.87 201.06 240.53 314.16
19.8 15.4 30.9 21.5 35.2 38.5 20.3 28.4 35.3 19.1 27.2 34.1 26.0 32.9 23.5 30.4 27.8 47.0 65.5 45.8 64.3 43.3 61.8 40.7 59.2 27.8 46.3 39.9 38.2 34.8 24.1 18.4 88.3 103.2 87.1 102.0 84.6 82.0 69.1 61.9 61.1 57.7 46.9 44.3 29.1 99.5 96.9 84.0 77.6 75.9 72.5 61.8 56.1 44.0 37.6 88.0 86.4 83.0 110.7 140.9 72.2 66.6 54.4 48.1 99.9 130.1 94.3 124.5 163.9 237.6 82.2 112.3 151.8 225.5 75.8 106.0 145.4 219.1 53.0 27.7 83.1 122.6 196.2 57.9 30.1 97.3 171.0 69.6 143.2 73.6

Area = R2, where = 3.141592654.

Note: Opening area minus pilot area equals total area to be removed by underreamer or hole opener.

Hydraulics Net Annular Area Removed with Underreamer or Hole Opener vs. Bit Pilot Hole
Bit Size Area in.
41 8 43 4 57 8 67 8 61 8 61 4 61 2 63 4 77 8 83 8 81 2 83 4 91 2 9 7 8 10 5 8 117 8 121 4 131 2 143 4 171 2 207 8 227 8 247 8 267 8 287 8
2

123

in.2
13.36 17.72 27.11 28.27 29.47 30.68 33.18 35.79 48.71 55.09 56.75 60.13 70.88 76.59 88.64 95.03 117.86 143.14 170.87 240.53 314.16 380.13 452.39 530.93 615.75

22.00 380.13

Opening Dia. (in.) 24.00 26.00 28.00 30.00 32.00 36.00 38.00 40.00 452.39 530.93 615.75 706.86 804.25 1,017.88 1,134.12 1,256.64

42.00 1,385.44

262.2 236.9 209.2 139.5 211.8 138.2 72.3 290.3 375.2 216.7 301.5 150.8 235.6 78.5 163.3 84.8 465.9 392.3 326.7 424.1 254.1 351.8 175.5 273.2 91.1 188.5 637.8 565.5 486.9 402.1 754.0 681.7 603.2 518.4 876.5 804.3 726.6 640.9 1,005.3 933.1 854.5 769.7

Area = R , where = 3.141592654.

Note: Opening area minus pilot area equals total area to be removed by underreamer or hole opener.

124

Hydraulics

Hydraulics
To ensure a successful underreaming job, it is very important to select the proper orifice sizes for the underreamer, bit or bullnose. Different jobs will require different orifice sizes based on parameters such as pilot hole size, underreamer opening diameter, flow rate, mud weight, etc. A good rule of thumb for flow is the following: 35 GPM x hole size = minimum; 50 GPM x hole size = maximum. Example: 105/8 in. hole to be underreamed to 121 4 in.: 35 x 121 4 in. = 429 minimum GPM 50 x 121 4 in. = 612 maximum GPM Correct Orifice Selection Orifice size controls the force at the top of the piston which pushes the cam down and opens the cutter. In a Reamaster or DTU, the total flow area of the combination of jets in the underreamer and bit or bullnose will determine the pressure drop in the system. The correct orifice size or TFA is necessary for proper operation of the tool. The following charts and examples will help you select the proper orifice size for your flow requirements. Reamaster and Drilling-Type Underreamers (DTU) Example: 16 in. duplex mud pump with 61 4 in. liner rated at 50 GPM 1. Find flow rate in GPM from pump volume tables located in the conversion/data tables (Section 7). 2. Use orifice curves on Page 126. Flow 400 GPM line into shaded area, until the GPM line intersects an orifice size line. This establishes the TFA for efficient tool operation. In this case, a combination of three (1232 or twelve) .330 TFA in a DTU and three (1232 or 12) in the bit .330 TFA will provide a system TFA of .660. This would be a 50/50 percent flow split. The corresponding pressure drop would be 340 psi at the piston. The 340 psi added to the total drillstring system losses will determine your actual standpipe pressure i.e., 1,600 psi losses in system plus 340 psi drop at tool = approximately 1,940 psi standpipe indication. When the GPM line intersects more than one orifice size line, either size is correct; but when available, an intersection at mid-range of the shaded area is recommended.

Hydraulics

125

K-Mill, SPX/Drag- and Rock-Type Underreamers Example: 16 in. duplex mud pump with 61 4 in. liner rated at 50 GPM 1. Find flow rate in GPM from pump volume tables located in the conversion data tables (Section 7). Flow rate is 350 GPM. 2. Use orifice curves on Page 126. Follow 350 GPM line into shaded area, until the GPM line intersects an orifice size line. This establishes the correct orifice size for efficient tool operation. In this case, either a 26 32 in. (TFA .590) or a 28 32 in. (TFA .601) orifice may be used. Corresponding pressure drops are 310 and 390 psi, respectively. When the GPM line intersects more than one orifice size line, either size is correct; but when available, an intersection at mid-range of the shaded area is recommended. SPX/Drag- and Rock-Type Underreamers with Flo-Tel Flo-Tel equipped underreamers signal the operator that the cutter arms are fully extended and the tool is underreaming at full gauge. The Flo-Tel device effectively substitutes a larger orifice when the cutter arms are extended. As a result, pressure on the pump gauge drops by approximately 200 lb. or the number of pump strokes increases. These clear signals from the Flo-Tel assure that the arms have opened completely, thus eliminating the need for any re-reaming or additional trips. We recommend using the Flo-Tel, especially when cutting a shoulder in hard formation.

126 OrificeSizes forfor Drilling-Type and Reamaster Underreamers Orifice Sizes Drilling-Type and Reamaster Underreamers
Orifice Size TFA
500 .186 .330 .389.450.518 .588 .665 .744 .831 .918 1.015 1.113

Hydraulics

1.217

1.323

400 Pressure drop (psi)

300

200 Orifice coefficient .95 10 lb/gal 75 lb/ft3

100

100

200

300

400

500

600

700

800

900

1,000

GPM

Orifice Sizes for K-Mill, SPX Drag- and Rock-Type Underreamers Orifice Sizes for K-Mill, SPX Drag- and Rock-Type Underreamers

Orifice Size 12/32 14/32 16/32 18/32 20/32 22/32 24/32 .110.150.196.249 .307 .371 .441 TFA
500

26 /32 28/32 .518 .601

30 /32 .690

32 /32 .785

11/8 .994

400 Pressure drop (psi)

300

200 Orifice coefficient .95 10 lb/gal 75 lb/ft3

100

100

200

300

400

500

600

700

GPM

Hydraulics

127

Determining System Hydraulics To calculate total system pressure (the standpipe pressure gauge reading) after selecting the correct orifice, use the following procedure. While marking a bit run before underreaming, run the mud pump at the underreaming flow rate (GPM). Record the standpipe pressure with a bit at the approximate underreaming depth. Refer to orifice curves on page 126. Find the top of the curve for the TFA of the bit. The intersection of the flow-rate line (GPM) with the orifice curves indicates the bit pressure drop at left, correct for mud weight other than ten lb/gal. See page 126. Subtract this bit pressure drop from the standpipe pressure previously recorded. This yields the bore and annular pressure losses. Add this number to the expected reading of standpipe pressure when underreaming. See the following example. Rock-Type Underreamer, Pumping Rate 250 gPM Given: 1. Approximate depth of bit 2. Number and size of bit nozzles 3. Flow rate when opening hole 4. Standpipe pressure at 250 GPM (from pump gauge) 5. Bit pressure drop (from orifice curves) 6. Bore and annular pressure losses 7. Flow rate (from #3) 8. Pressure drop across underreamer (from orifice curves, 24 32 in. = .441 TFA orifice see page 126) 9. Expected standpipe pressure (add #6 and #8)

5,428 ft. 3 - 14 32 in. (.450 TFA) 250 GPM 600 psi

Find:

280 psi 320 psi 250 GPM 290 psi 610 psi

128

Hydraulics

Pressure Drops for Mud Weights Other than Ten lb/gal. Mud Weight Volume Pressure Drop (P) Across Nozzle of Indicated Dia. Flow P in psi (in.) Rate in 12/ 14/ 16/ 18/ 20/ 22/ 24/ 26/ 28/ 32/ 32 32 32 32 32 32 32 32 32 32 gPM TFA .110 .150 .196 .249 .307 .371 .441 .519 .601 .785
50 60 70 80 90 100 110 120 130 140 150 160 180 200 220 240 260 280 300 320 340 360 380 400 450 500 600 700 800 900 1,000 189 272 370 483 611 200 261 330 408 493 587 689

11/8 .994

11/4 1.227

239 289 344 404 468 537 611

215 252 292 336 382 483 597

192 220 251 317 391 474 564 661

217 267 323 385 452 524 601 684

189 228 272 319 370 425 483 545 611

197 232 269 308 351 396 444 495 548 694

200 229 261 294 330 368 408 516 637

216 239 303 374 538

189 233 336 457 597

220 300 392 496 612

Hydraulics Pressure Drops for Mud Weights Other than Ten lb/gal. Pressure from across the orifice is directly proportional to the mud weight. Therefore, if the circulating fluid has weight other than ten lb/gal., the correct pressure drop can be determined by multiplying the figure obtained for the table by the factor: Actual mud weight (lb/gal.) 10 Example: If 130 GPM of 12.5 lb/gal. fluid is being circulated through a 1632 in. (.196 TFA) nozzle, the pressure drop is as follows: 1. From the table (130 GPM, 16 32 in. nozzle): Pressure drop = 404 psi (for ten lb/gal. mud) 2. 404 x 12.5 = 505 psi 10 The correct pressure drop of 130 GPM of 12.5 lb/gal. mud, circulated through a 16 32 in. nozzle, is 505 psi.

129

130 Jet Combinations for Hydraulic Tools

Jet Size (in.) Diffuser Std. Jet Jet 32 7 8 9 8 /32 10 9 /32 11 10 /32 12 11 /32 13 12 /32 14 15 13 /32 16 14 /32 17 15 /32 18 16 /32 19 20 22 24 26 28 30 32 1116 118 114 138 112 Number of Jet Nozzles

Hydraulics

1 0.038 0.049 0.062 0.077 0.093 0.110 0.130 0.150 0.173 0.196 0.222 0.249 0.277 0.307 0.371 0.442 0.519 0.601 0.690 0.785 0.887 0.994 1.227 1.485 1.767

2 0.076 0.098 0.124 0.154 0.186 0.220 0.260 0.300 0.346 0.392 0.444 0.498 0.554 0.614 0.742 0.884 1.038 1.202 1.380 1.570 1.774 1.988 2.454 2.970 3.534

3 0.114 0.147 0.186 0.231 0.279 0.330 0.390 0.450 0.519 0.588 0.666 0.747 0.831 0.921 1.113 1.326 1.557 1.803 2.070 2.355 2.661 2.982 3.681 4.455 5.301

4 0.152 0.196 0.248 0.308 0.372 0.440 0.520 0.600 0.692 0.784 0.888 0.996 1.108 1.228 1.484 1.768 2.076 2.404 2.760 3.140

5 0.190 0.245 0.310 0.385 0.465 0.550 0.650 0.750 0.865 0.980 1.110 1.245 1.385 1.535 1.855 2.210 2.595 3.005 3.450 3.925

6 0.228 0.294 0.372 0.462 0.558 0.660 0.780 0.900 1.038 1.176 1.332 1.494 1.662 1.842 2.226 2.652 3.114 3.606 4.140 4.710

7 0.266 0.343 0.434 0.539 0.651 0.770 0.910 1.050 1.211 1.372 1.554 1.743

8 0.304 0.392 0.496 0.616 0.744 0.880 1.040 1.200 1.384 1.568 1.776 1.992

9 0.342 0.441 0.558 0.693 0.837 0.990 1.170 1.350 1.557 1.764

10 0.380 0.490 0.620 0.770 0.930 1.100 1.300 1.500 1.730 1.960

11 0.418 0.539 0.682 0.847 1.023 1.210 1.430 1.650 1.903 2.156

12 0.456 0.588 0.744 0.924 1.116 1.320 1.560 1.800 2.076 2.352

Area = r2, where = 3.141592654.

Hydraulics Mud Weight (7 to 13.9 lb/gal.) (52.36 to 103.97 lb/ft.3)

lb/gal. bl/ft.3pt Specific gravity
0.84 0.85 0.86 0.88 0.89 0.90 0.91 0.92 0.94 0.95 0.96 0.97 0.98 0.99 1.00 1.02 1.03 1.04 1.06 1.07 1.08 1.09 1.10 1.12 1.13 1.14 1.15 1.16 1.18 1.19 1.20 1.21 1.22 1.24 1.25

131

gradient psi/100 ft. depth

36.33 36.86 37.38 37.89 38.41 38.93 39.45 39.97 40.49 41.01 41.53 42.05 42.57 43.08 43.29 44.12 44.65 45.17 45.68 46.20 46.72 47.24 47.76 48.27 48.80 49.32 49.84 50.36 50.87 51.39 51.91 52.43 52.95 53.47 53.99

lb/gal.

lb/ft.3

Specific gravity
1.26 1.27 1.28 1.30 1.31 1.32 1.33 1.34 1.36 1.37 1.38 1.39 1.40 1.42 1.43 1.44 1.45 1.46 1.48 1.49 1.50 1.51 1.52 1.54 1.55 1.56 1.57 1.58 1.60 1.61 1.62 1.63 1.64 1.66 1.67

gradient psi/100 ft. depth

54.51 55.03 55.55 56.06 56.58 57.10 57.62 58.14 58.66 59.18 59.70 60.22 60.74 61.25 61.77 62.29 62.81 63.33 63.85 64.37 64.89 65.41 65.93 66.44 66.96 67.48 68.01 68.53 69.04 69.56 70.08 70.60 71.12 71.63 72.16

7.0 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.9 8.0 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 8.9 9.0 9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 9.9 10.0 10.1 10.2 10.3 10.4

52.36 53.11 53.86 54.60 55.35 56.10 56.85 57.60 58.34 59.09 59.84 60.59 61.34 62.08 62.38 63.58 64.33 65.08 65.82 66.57 67.32 68.07 68.82 69.56 70.31 71.06 71.81 72.56 73.30 74.05 74.80 75.55 76.30 77.04 77.79

10.5 10.6 10.7 10.8 10.9 11.0 11.1 11.2 11.3 11.4 11.5 11.6 11.7 11.8 11.9 12.0 12.1 12.2 12.3 12.4 12.5 12.6 12.7 12.8 12.9 13.0 13.1 13.2 13.3 13.4 13.5 13.6 13.7 13.8 13.9

78.54 79.29 80.04 80.78 81.53 82.28 83.03 83.78 84.52 85.27 86.02 86.77 87.52 88.26 89.01 89.76 90.51 91.26 92.00 92.75 93.50 94.25 95.00 95.74 96.49 97.24 97.99 98.74 99.48 100.23 100.98 101.73 102.48 103.22 103.97

132 Mud Weight (14 to 20 lb/gal.) (104.72 to 149.60 lb/ft.3)

lb/ gal.
14.0 14.1 14.2 14.3 14.4 14.5 14.6 14.7 14.8 14.9 15.0 15.1 15.2 15.3 15.4 15.5 15.6 15.7 15.8 15.9 16.0 16.1 16.2 16.3 16.4 16.5 16.6 16.7 16.8 16.9

Hydraulics

lb/ft.3

Specific gravity
1.68 1.69 1.70 1.72 1.73 1.74 1.75 1.76 1.78 1.79 1.80 1.81 1.82 1.84 1.85 1.86 1.87 1.88 1.90 1.91 1.92 1.93 1.94 1.96 1.97 1.98 1.99 2.00 2.02 2.03

gradient psi/100 ft. depth

72.68 73.20 73.72 74.32 74.75 75.27 75.79 76.31 76.83 77.35 77.87 78.39 78.91 79.42 79.94 80.46 80.98 81.50 82.07 82.54 83.06 83.58 84.10 84.61 85.13 85.65 86.17 86.89 87.21 87.73

lb/gal.

lb/ft.3

Specific gravity
2.04 2.05 2.06 2.08 2.09 2.10 2.11 2.12 2.14 2.15 2.16 2.17 2.18 2.20 2.21 2.22 2.23 2.24 2.26 2.27 2.28 2.29 2.30 2.32 2.33 2.34 2.35 2.36 2.38 2.39 2.40

gradient psi/100 ft. depth

88.25 88.77 89.29 89.80 90.32 90.84 91.37 91.89 92.40 92.92 93.44 93.96 94.48 94.99 95.51 96.04 96.56 97.08 97.59 98.11 98.63 99.15 99.67 100.19 100.71 101.23 101.75 102.27 102.78 103.30 103.82

104.72 105.47 106.22 106.96 107.71 108.46 109.21 109.96 110.70 111.45 112.20 112.95 113.70 114.44 115.19 115.94 116.69 117.44 118.18 118.93 119.68 120.43 121.18 121.92 122.67 123.42 124.17 124.92 125.66 126.41

17.0 17.1 17.2 17.3 17.4 17.5 17.6 17.7 17.8 17.9 18.0 18.1 18.2 18.3 18.4 18.5 18.6 18.7 18.8 18.9 19.0 19.1 19.2 19.3 19.4 19.5 19.6 19.7 19.8 19.9 20.0

127.16 127.91 128.66 129.40 130.15 130.90 131.65 132.40 133.14 133.89 134.64 135.39 136.14 136.88 137.63 138.38 139.13 139.88 140.62 141.37 142.12 142.87 143.62 144.36 145.11 145.86 146.61 147.36 148.10 148.85 149.60

Hydraulics Areas of Circles and Nozzles (in.)

Nozzle Size
7 8 9 10 11 12 13 14 15 16 17 18 20 22 24 26 28

133

Dia.
1 1 3

Area
.000767 .003068 .006903 .01227 .01917 .02761 .03758 .04909 .06213 .07670 .09281 .1104 .1296 .1503 .1726 .1963 .2217 .2485 .2769 .3068 .3382 .3712 .4057 .4418 .4794 .5185 .5591 .6013 .6450 .6903 .7371 .7854

Dia.
118 1 4
1

Area Dia.
.9940 1.2272 1.4849 1.7671 2.0739 2.4053 2.7612 3.1416 3.5466 3.9761 4.4301 4.9088 5.4119 5.9396 6.4918 7.0686 7.6699 8.2958 8.9462 9.6212 10.3206 11.0447 11.7933 12.566 13.364 14.186 15.033 15.904 16.800 17.721 18.665 19.635 518 5 4
1

Area
20.629 21.648 22.691 23.758 24.850 25.967 27.109 28.274 29.465 30.680 31.919 33.183 34.472 35.785 37.122 38.485 39.871 41.282 42.718 44.179 45.664 47.173 48.707 50.266 51.849 53.456 55.088 56.745 58.426 60.132 61.862 63.617

Dia.
918 914 938 9 2
1

Area
65.397 67.201 69.029 70.882 72.760 74.662 76.589 78.540 80.516 82.516 84.541 86.590 88.664 90.763 92.886 95.033 97.205 99.402 101.623 103.869 106.139 108.434 110.753 113.10 115.47 117.86 120.28 122.72 125.19 127.68 130.19 132.73

32 16 32 8 32 16 32 4 32 16 32 8 32 32 2 32 32 8 32 32 4 32 16 32 8 32 16 32

138 1 2
1

538 5 2
1

1 5 3 7

158 1 4
3

558 5 4
3

958 9 4
3

178 2 2 8
1

578 6 6 8
1

978 10 10 8
1

1 9 5

214 238 2 2
1

614 638 6 2
1

1014 1038 10 2
1

11

3 13 7

258 2 4
3

658 6 4
3

1058 10 4
3

16

15

278 3 3 8
1

678 7 7 8
1

1078 11 11 8
1

1 17 9

16

314 338 312 3 8

5 3

714 738 712 7 8

5 3

1114 1138 1112 1158 11 4

3

19

5 21 11

16

3 4 378 4 4 8
1

7 4 778 8 8 8
1

23

1178 12 12 8
1

3 25 13 27

414 438 412 4 8

5 3

814 838 812 8 8

5 3

1214 1238 1212 1258 12 4

3

7 29 15 31

4 4 478 5

8 4 878 9

1278 13

Area = r2, where = 3.141592654.

134 Areas of Circles and Nozzles (in.) (continued)

Nozzle Dia. Size
1318 13 4
1

Hydraulics

Area
135.30 137.89 140.50 143.14 145.80 148.49 151.20 153.94 156.70 159.48 162.30 165.13 167.99 170.87 173.78 176.71 179.67 182.65 185.66 188.69 191.75 194.33 197.93 201.06 204.22 207.39

Dia.
1638 16 2
1

Area
210.60 213.82 217.08 220.35 223.65 226.98 230.33 233.71 237.10 240.53 243.98 247.45 250.95 254.47 258.02 261.59 265.18 268.80 272.45 276.12 279.81 283.53 287.27 291.04 294.83 298.65

Dia.
1958 19 4
3

Area
302.49 306.35 310.24 314.16 318.10 322.06 326.05 330.06 334.10 338.16 342.25 346.36 350.50 354.66 358.84 363.05 367.28 371.54 375.83 380.13 384.46 388.82 393.20 397.61 402.04 406.49

Dia.
2278 23 2318 2314 2338 23 2
1

Area
410.97 415.48 420.00 424.56 429.13 433.74 438.36 443.01 447.69 452.39 457.11 461.86 466.64 471.44 476.26 481.11 485.98 490.87 495.79 500.74 505.71 510.71 515.72 520.77 525.84 530.93

1338 13 2
1

1658 16 4
3

1978 20 2018 20 4
1

1358 13 4
3

1678 17 1718 17 4
1

1378 14 1418 14 4
1

2038 20 2
1

2358 23 4
3

1738 17 2
1

2058 20 4
3

2378 24 2418 24 4
1

1438 14 2
1

1758 17 4
3

2078 21 2118 21 4
1

1458 14 4
3

1778 18 1818 18 4
1

2438 24 2
1

1478 15 1518 1514 15 8

3

2138 21 2
1

2458 24 4
3

1838 1812 18 8
5

2158 2134 21 8
7

2478 25 21 8
1

1512 15 8
5

1834 18 8
7

22 22 8
1

2514 25 8
3

1534 15 8
7

19 19 8
1

2214 22 8
3

2512 25 8
5

16 16 8
1

1914 19 8
3

2212 22 8
5

2534 25 8
7

1614

1912

2234

26

Area = r2, where = 3.141592654.

Hole Opening

135

Definintion of Hole opening

Hole opening is defined as enlarging the wellbore with a cutter of a fixed diameter, unlike an underreamer which is activated hydraulically to a predetermined diameter and then closed to a smaller diameter once interval is completed. Hole openers are typically used to enlarge previously drilled pilot holes. This enlargement is often necessary to ensure adequate clearance for the casing and cement. For example, a 121 4 in. bit would drill the pilot hole. A 171 2 in. hole opener would then be run in order to provide enough room to run and cement the 133 8 in. casing. Smith offers a full range of hole openers, as well as the complete line of hole enlargers: Fixed Diameter Hole Opener (FDHO) with GTA cutters up to 40 in. opening diameter. Master Driller with cone segment cutters opening up to 36 in. diameter. Master Driller available with Polycrystalline Diamond Compact (PDC) cutters in requested sizes. Hole enlargers available in 26 varying sizes up to 26 in. opening diameter.

136 Weights and Rotary Recommendations for Hole Openers/Hole Enlargers Hole Size Cutter Type Weight (lb.)

Hole Opening

Rotary Speed (RPM)

50 - 75 90 - 120 125 - 150 125 - 150 125 - 150 50 - 75 90 - 100 90 - 100 90 - 100 75 - 85 50 - 75 60 - 65 35 - 40 60 - 65 35 - 45 60 - 65 35 - 45 50 - 60 30 - 40

Soft Formations (Soft Shale, Sand, Red Beds): 578 - 778 Milled Tooth 5,000 - 10,000 818 - 11 Milled Tooth 10,000 - 15,000 1114 - 1514 Milled Tooth 10,000 - 25,000 1512 - 1912 Milled Tooth 10,000 - 25,000 1934 - 26 Milled Tooth 15,000 - 25,000 Medium Formations (Medium Shale, Sand, Lime): 578 - 778 Milled Tooth 5,000 - 10,000 818 - 11 Milled Tooth 10,000 - 20,000 1114 - 1514 Milled Tooth 15,000 - 30,000 1512 - 1912 Milled Tooth 15,000 - 30,000 1934 - 26 Milled Tooth 20,000 - 35,000 Hard Formations (Hard Lime, Dolomite, Quartzite): 578 - 778 Button Type 10,000 - 15,000 25,000 - 30,000 1 8 8 - 11 Button Type 25,000 - 30,000* 35,000 - 45,000 1114 - 1514 Button Type 30,000 - 45,000* 35,000 - 50,000 1 1 15 2 - 19 2 Button Type 30,000 - 50,000* 35,000 - 45,000 3 19 4 - 26 Button Type 30,000 - 45,000* *TCI button type for extremely hard formations. Note: All dimensions are given in inches unless otherwise stated.

GTA Hole Openers/Hole Enlargers Size

778 - 1334 (Incl.) 14 - 1712 (Incl.) 18 - 26 (Incl.) 27 - 42 (Incl.) 43 and Larger + 116 + 332 + 18 + 532 + 316

Tolerance
- 132 - 116 - 116 - 116 - 116

Notes: 1. All dimensions given in inches unless otherwise stated. 2. The above gauge diameters apply to GTA, STA, Master Driller and hole enlargers. 3. Unlike rock bits, the gauge area of the cutters is as dressed and not ground. 4. Above gauge tolerances are not applicable to those orders that require specific gauge diameters. (Some applications may require tighter gauge control.) 5. The above gauge diameters apply to milled tooth and TCI cutting structures.

Hole Opening Master Driller Hole Opener

137

138

Hole Opening

Master Driller
The Master Driller is well suited for soft to medium-hard formations where a variety of hole sizes and formations are encountered. The tool is also used where rotary table size restrictions exist. One body can accommodate several sizes for arms; an advantage in locations with limited rig space or logistics problems. Cutter arms may be installed below the rotary table when rotary table size restrictions exist. The tool utilizes specifically designed cones for hole openers. A large selection of cones including milled tooth, TCI and PDC cutters. All Master Driller hole openers feature replaceable nozzles to assure effective hole cleaning and to cool cutter cones. Bottom box connection allows the selection of bit or bullnose for guidance. Master Driller Tool Servicing It is advisable to clean the tool after use and before storage. Steam cleaning is preferred but washing in petroleum solvent or diesel fuel is acceptable. If the tool is painted prior to storage, avoid letting paint run into the arm pin holes and into the cone bearing races. Coat the tool joint connections with a good grade of thread lubricant and reinstall the thread protectors supplied with tool. Changing Cutters Remove 3 8 in. arm pin retaining screws, 1 2 in. for Series 15000-2 Master Driller. Using drift punch furnished with tool, knock the arm pins out toward arm pin retaining screw holes. Discard arm pins and arm pin retaining screws as new pins and screws are furnished with each set of arms. Replace new cutter arm in pocket, grease lightly and install new arm pins and new arm pin retaining screws. Changing Jet Orifice Clean threads in orifice seat. Install new O-ring packing in O-ring groove on jet, grease lightly and screw jet into seat. Jet nozzles are available in all standard sizes (32nd increments).

Hole Opening Changing Arm Pin Bushings After a number of sets of cutters have been run in the tool, the arm pins will become loose when installed in the arm pin holes. This is due to wear in the arm pin bushings, and the bushings should be replaced. These bushings may be pressed or driven out and replaced by new bushings. The bushing on the side with the arm pin retaining screw may be removed in either direction. The bushing on the other side can only be removed toward the arm pocket. Heat is neither necessary nor desirable in the removal of the bushings. After the arm pin holes have been cleaned and lightly greased, the greased arm pin bushings may be replaced by pressing or driving into place. Replace the short bushing in the side without the arm pin retaining screw first. Body Examine the body for excessive wear. Critical areas are as follows: 1. The hardfaced edge of the pilot wiper pads. 2. The shirttail area of the cutter segment. 3. Jet nozzles and jet nozzle retainer sleeves.

139

140 Master Driller

Hole Opening

Body diameter Fishing neck diameter Top pin connection

Fishing neck length

Overall length

Bottom box connection

Standard opening diameter

Bottom neck diameter

Hole Opening Master Driller Specifications Body Std. Min. Body Series Opening Pilot Dia. Dia. Hole
8200 9500 11000 15000 1214 1214 1434 1712 22 8
5

141

Fishing Neck Overall Connections Length API Reg. Length Dia.

24 24 24 24 24 24 24 24 8 8 8 8 8 10 10 10 60 67 67 70 70 74 74 74

Wt. (lb.)

812 812 912 912 9 2

1

814 912 912 1158 11 8

5

Top Bottom Pin Box

658 658 658 658 6 8
5

412 658 658 658 658 758 758 758

640 915 915 1,100 1,100 1,900 1,900 1,900

1712 2658 3658

912 1214 2458

1558 1558 1558

758 758 758

Notes: 1. All dimensions are given in inches unless otherwise stated. 2. All weights are approximate.

Ordering Instructions: When ordering or requesting quotations on the Master Driller, please specify: 1. Body series 2. Hole opening size 3. Pilot hole size 4. Top and bottom connections, if other than standard 5. Fishing neck diameter, if other than standard 6. Type of formation (soft, medium)

142 GTA Fixed Diameter Hole Openers

Hole Opening

Hole Opening

143

gta fixeD DiaMeter Hole openers

These tools are primarily used for surface holes and conductor casing. The selection of cutters allows the tool to handle a wide range of formations from soft to hard-abrasive. Features GTA cutter sizes available from 26 to 42 in. The GTA hole openers feature demountable cutters which are easily replaced on the rig floor. GTA hole openers are available with sealed bearing milled tooth or tungsten carbide insert cutters. Tools feature long fishing necks which can be made up below the rotary because of size limitations. All GTA hole openers feature replaceable nozzles to assure effective hole cleaning. GTA Tool Servicing Wash down the hole opener as soon as possible after it is pulled. Clean the mud and cuttings off the cutters, from between each cutter, the leg bearing surfaces and out from the cutter in the throat of the leg. Clean the wrench slots in the jet nozzle retainer. Flush the circulation passages with water until full flow can be seen from all nozzles and the ID to the box connection. Allow the hole opener to drain dry. Blow out the circulation passages, if possible. Nozzles Use the jet nozzle wrench to remove the nozzle retainer from the sleeve. Clean and inspect all jet nozzle sleeve threads. Check the O-ring seal surface at the bottom of the bore. Make sure that the surfaces are clean and undamaged. If the threads are damaged, rechase them with a 11 2 in. 12 NF tap to a minimum depth of 3 4 in. Inspect the O-ring for cuts, abrasion or other damage. If the O-ring is damaged or shows signs of permanent set, replace it. Check the retainer and jet nozzle. Make sure that the threads and O-ring sealing surfaces are clean and undamaged. Examine the jet nozzle for cracks, nicks and erosion damage. If either the retainer or the jet nozzle appear damaged, replace the assembly with a Smith Tool 95 Series jet nozzle with the required orifice diameter. To replace the jet nozzle, first grease the O-ring and install it in the sleeve below the threaded section and then grease the sleeve threads. Apply a coat of grease to the O-ring sealing surface and the threads of the retainer and screw the retainer into the sleeve. Tighten the retainer with the jet nozzle wrench.

144

Hole Opening Cutters and Legs If the cutters are reusable, regrease immediately. Remove the outer retainer pin for access to the lube fitting, and pump a high-quality molydenum disulfide-base grease through the main pin into the center of the bearing sleeve. Rotate the cutter while pumping to distribute the grease through the bearing. If necessary, remove the cutters to inspect the legs and main pins for wear or damage. The cutters may be removed as follows: 1. GTA main pins are released by removing the 7 8 in. 12 NF set screw in the main pin end then slip the retainer pin sideways out of the main pin and leg. Note: A single retainer pin is used in the outer leg on small diameter hole openers. The inner end of the main pin is inaccessible. 2. The main pin can now be pulled with the main pin puller. On GTA main pins use the 7 8 in. set screw hole threads. 3. Use the sliding hammer portion of the puller to jar the main pin until it slides free of the cutter assembly and the leg. The cutter will now lift out of the body. 4. Use solvent to wash clean the entire main pin, cutter assembly bore, leg faces and leg bores. Inspect all mating surfaces for galling, damage or excessive wear. 5. If the main pin is worn or damaged it must be replaced. Replacement main pins are furnished with new grease fitting, retaining pins and set screws. 6. If the cutter bearing sleeve is damaged, rebuild the cutter in accordance with the tool kit manual. Rebuilding the sleeve and the leg should not exceed .040 in. 7. The clearance between the end of the cutter bearing sleeve and the leg should not exceed .040 in. The leg should be replaced if: 1. The main pin bore is damaged or measures in excess of 2.520 in. 2. The anti-rotation flat (for the sleeve) on the leg is deformed in excess of .060 in. Any cracks are detected by magnetic particle inspection. Replacement will be as follows. Welding materials 1. Use 1 8 or 3 16 in. AWS E7018 low hydrogen rod. 2. Weld rod coating must be kept dry to prevent hydrogen embrittlement. Store at 200F (93C) after opening container. If rod has been exposed to humid air, bake rod one hr. at 700F (371C). DO NOT bake at any temperature over 800F (427C).

Hole Opening 3. Use machine setting of 30 to 35 volts at 130 to 150 amps for 3 16 in. rod. Leg removal 1. Use 3 8 in. carbon arc for removal and shop air at 90 psi minimum. Machine setting is 70 to 80 volts at 300 to 350 amps. 2. Start leg removal by air arcing a gouge on front of the leg 1 8 in. above the base plate to locate the seam. Remove the weld all the way around leaving the weld across the back until last. This procedure is also correct for leg removal. 3. Grind remaining base as required to remove all slag and carbon deposits. Leg attachment 1. All legs are supplied with temporary steel straps welded on both sides of the leg to minimize distortion. Leave the straps in place until assembly welding is done. 2. Leg base weld bevels should be ground or air arced to remove any precipitated carbides prior to welding. 3. Remove all grease, dirt or paint from the areas to be welded. 4. Set dowel pins and position the legs. Check the correct hole opener gauge diameter with new cutter assemblies temporarily in place. 5. Tack weld the leg with one in. long beads on all four sides. Use 1 8 or 3 16 in. AWS E7018 rod. 6. Preheat the base of the leg to 150F (66C) and verify temperature with a TEMPSTIK. Deposit root pass using 3 16 in. AWS E7018 rod. Make alternate or staggered pass pattern on sides of leg. All welds will be multiple pass fillet or bevel welds. Interpass temperature on all welds will be 250F (121C). Machine setting: 30 to 35 volts at 130 to 150 amps. 7. Remove slag and peen welds. Peening of all welds is recommended to induce favorable residual stresses and prevent cracking. Peening should be hard enough to cause the surface to yield. Peening, however, will not remove locked-in stress if the weld metal is cool when peened. It is recommended that each pass be peened immediately after depositing weld metal. 8. Magnetic particle inspect all welds and repair as required. 9. Remove the straps and grind off excess tack welds. 10. Leg attachment is done as per paragraphs two through eight using a special leg positioning fixture. Anchor and fixture main pin to the body with a rod or bolt. Slip a cutter assembly and the new leg onto the fixture main pin with a 0.040 in. shim between the cutter and the leg. Put the tapered block, washer and nut on the pin and tighten the entire assembly into position. Weld as specified above.

145

146

Hole Opening 11. Final ring gauging is required using new cutters to ensure that the correct hole opener diameter has been maintained (see hole opener gauge tolerances on page 136). Leg tolerances 1. After installing a new cutter assembly and main pin, the total clearance between the cutter bearing sleeve and the leg face should be no greater than 0.040 in. nor less than 0.020 in. 2. Peening: Straightening of a leg by peening is recommended when necessary. Opening of leg for proper clearance is done by peening on the inside of the yoke. For closing the leg, peen on the outside. 3. Heating: Straightening a leg by heating, although satisfactory, requires extreme care that the carburized main pin bores do not exceed 425F (218C) at any time. The leg uprights may be heated to a maximum of 1,200F (649C), if necessary, providing the 425F (218C) temperature of the pin bore is not exceeded. Temperatures during this procedure shall be verified by TEMPSTIK. Body Repair Examine the body for excessive wear. Critical areas are as follows: 1. The hardfaced edge of the pilot hole reamer plates supporting the circulation jet nozzles 2. The shirttail area of the leg 3. Nozzle retainer sleeves 4. The milled surface on the outer portion of the leg Hardfaced surfaces may be repaired in the field. The resulting metal deposit will not equal the hardness of the tungsten carbide, but if properly applied, it will give additional wear protection to the hole opener body. 1. Use welding rods equivalent to Servcotube 40 to 60 mesh in 3 16 or 5 32 in. diameters. 2. Set the welding machine for 150 to 200 amp at 30 to 40 volts for 5 32 in. rod, 200 to 260 amp at 30 to 40 volts for 3 16 in. rod. AC or DC, either polarity may be used. 3. Preheat the area to be resurfaced to 300F (149C) to 400F (204C). CAUTION: DO NOT heat the carburized bore of the leg above 425F (218C), under any conditions. 4. Apply the hardfacing as stringer or weaving beads in two passes to a maximum thickness of 1 4 in. If weaving beads are applied, the bead width shall not exceed 21 2 times the rod diameter.

Hole Opening Cutter Installation Wipe a light coat of grease on the main pin, leg bores and cutter bearing sleeve bore (be sure O-rings are in place in the sleeve bore). Position the cutter in the leg with the anti-rotation lug flush on the flat on the outer portion of the leg. Push the main pin through the leg and bearing sleeve bore and into the inner leg until the retaining pin holes are aligned. CAUTION: The square end of the gauge main pin is the inboard end and the beveled end will be flush or slightly below the outboard face of the leg. Using the notch in the end of the main pin, rotate the main pin until the retainer pin holes are aligned with the holes in the leg. Insert the retainer pins with the flat side out toward the set screw hole and centered on the set screw hole. The screwdriver slot in the end of the retainer pin is parallel with the flat to help with alignment. Tighten the set screws to 100 ft/lb. torque maximum. Cutters from stock should already be fully greased. However, the cutters may be regreased while on the body. Corrosion Prevention After thorough cleaning, coat the following surfaces with a quality rust-preventative compound. Tool joint threads and shoulders Inner faces of the legs or in the case of smaller bodies, the leg and body faces Main pin bores of the leg Cutter bearing sleeve ends and main bore

147

148 GTA Hole Opener

Hole Opening
Fishing neck diameter

Top pin connection

Fishing neck length

Overall length

Bottom neck length Bottom neck diameter Standard opening diameter

Bottom box connection

Hole Opening GTA Hole Opener Specifications

Std. Min. Pilot Fishing Neck Bottom Neck Body Opening Hole Dia. Length Dia. Top Pin Length Dia. Bottom Length Min. Dia. Conn. API Box Bore Reg. Conn. Dia. API Reg.
26 28 30 32 34 36 38 40 42 14 16 18 20 22 24 26 28 30 60 60 60 60 60 60 60 60 60 1912 19 8
7

149

658 - 758 6 8 - 7 8
5 5

12 12 12 15 15 15 15 15 15

912 9 2
1

758 758 758 858 858 8 8

5

96 96 100 100 101 103 106 106 106

1 1 2 2 2 3 3 3 3

1978 10 10 10 10 10 10

658 - 758 758 - 858 758 - 858 7 8 - 8 8

5 5

912 912 912 9 2

1

858 8 8
5

912 9 2
1

858 8 8
5

858

912

758

Notes: 1. All dimensions are given in inches unless otherwise stated. 2. All weights are approximate. 3. Replacement cutter sets include all parts necessary for replacement. 4. Cutter bearing rebuild kits are available on special order. Ordering Instructions for Cutters: When ordering or requesting quotations on cutters, please specify: 1. Hole size 2. Soft or medium formation 3. Milled tooth or tungsten carbide insert type cutter. Tungsten carbide insert

cutters are available for GTA and STA hole openers. Ordering Instructions: When ordering or requesting quotations on the GTA hole opener, please specify: 1. Pilot hole size 2. Hole opening size 3. Top and bottom connections, if other than standard 4. Fishing neck diameter, if other than standard 5. Specifications for intermediate sizes or sizes larger than 42 in. are available upon request.

150 Hole Enlargers

Hole Opening

Model 6980 hole enlarger, standard type, with pin up/box down

Directional model hole enlarger with one-piece body

Hole Opening

151

Hole enlarger
Hole enlargers are available in 26 sizes to provide hole enlargements from six through 36 in. Body Types Standard model furnished box down for use with a rock bit as the pilot, but also may be used with a bullnose. Bullnoses specified either round or sidehill. Directional model has an integral bullnose or stinger down. Cluster model, with four to six cutters, is for holes larger than 26 in., opening a 171 2 in. hole to 36 or 42 inches in a single pass. Features Rigid locking system improves safety and service life of cutter by eliminating rotation of the sleeve, yet allowing the cutter to rotate freely on ball and roller bearings. Jet circulation and efficient tool design provides low cost-per-foot cutting. Jet nozzles, positioned between each of the three cutters direct flow to shoulder of enlarged hole, can be changed to accommodate pump capacities or hydraulics programs. Rig floor cutter replacement is fast and easy with no need for cutting torches or welding. Cutter interchangeability allows a given cutter size to be used in more than one body size. Long-term reliability provided by ease of part replacement or repair of cutter arms and jet holders, ensuring long life and full return on tool investment. Ability to match to formation provides the correct cutting structure for the rock type, thus maximizing tool performance.

152

Hole Opening

0625-2600 M6980 Hole enlarger BoDies fielD repair anD service proceDures
Design and Construction Background 1. 0625-1250 Machined bar stock bodies, three pocket jets (recent mfg. 1250 has three wing jets) 2. 1550-2600 Cast-steel bodies, three pocket jets and three wing jets (two types of wing-jet holder designs available) 3. 1550-2600 Bar stock bodies, three pocket jets and three wing jets (two types of wing-jet holder designs) 4. Jets behind the pockets are mounted in a jet holder that is welded into the body. Standard wing jets are held by wash pipes that are welded into position in a channel formed by a pair of wing jet guardrails. The water passage is completed by cover plates between the body and the wash pipe. A plate is also welded at the top of the wash pipe to the guardrails as a mechanical protector prevents wash pipe damage. 5. In the factory, the bodies are assembled using gauges, fixtures, etc. For field repair, actual new cutter may be used as a gauge. 6. Cross lock pins (holds cutter pin to the arm) a. Double spring pins best suited for soft digging jobs using soft milled tooth cutters or medium formation hard formation milled tooth cutters. On 1550 and larger tools, a second type is in use: b. Solid pins held in place by concentric (double) short spring pins. Intended for button cutters or hard digging jobs. It is the intent of the design that arm pins and bushings are the main expendable wear components in the service life of the tool body. In soft digging, body will generally come out with no body repair required so the arm-bushing servicing is a long-range requirement. On the other hand, in extremely hard digging, the arms as well as bushings may require the same servicing as the cutters.

Hole Opening Repairs After each run or prior to the next run, inspect the tool.Wash cutters and tool body. Mag inspect tool/joints. Visually evaluate the following wear areas: 1. If cutter is in good shape and will be rerun (i.e. will not be removed from the body) the body must meet the following criteria: a. Check arms shirttail area negligible wear since cutter must be to gauge. b. Check cutter pin to arm hole clearance. Should be less than 1 64 in. c. Check cross pin locks. If using double spring pins and no sign of corrosion, and cutter pin end appears properly oriented, one can assume spring pins are ok. It is prudent precaution to replace if time permits. d. No signs of washout on body, jets/holders area. e. Wings hardface still visible. f. No lower necks, excessive wear or cracks on bit straps welds. g. Tool/joints passes mag inspection. 2. If cutter has some degree of wear and decision is not to rerun, wash body and cutter and arrange to remove cutters from body as soon as possible to prevent parts from being rust frozen. a. Bushings remove and replace if: Cam ear damaged (cracked, deformed). Hole for pin is worn oversized or elongated. Use a new pin to check. Maximum clearance 132 in. Evidence of cracks in weldment. b. Washpipes If any indication of leaks past seals of jets, remove snap rings, O-rings and jets. While the jet nozzles are out of the washpipe, check ID of washpipe for traces of erosion, washout and plugging. If ok, replace O-rings, jet nozzles and snap rings. Grease O-rings to facilitate assembly. Grease jet nozzle cavities in the washpipe ends. If indications of washout are present, return to service facility for repair. c. Pocket jet holders Erosion cutting across O-ring grooves and excessive body cutter pocket wear could necessitate replacing the holder. If required, return to service facility for repair. d. Lower neck Regular bodies (box joint). Due to the practice of strapping pilot bits to the hole enlarger lower neck, cracks are generated on the welds/edge of welds. This is probably due to the use of welding rods not compatible with the material of the body or welding procedure. If cracks are present, return to a service facility for repair.

153

154

Hole Opening

1. SM

2. H

3. Chisel Button

4. Conical Button

5. Ovoid/Ogive Button

1. Type SM for soft to medium formations: Non-sealed: IADC Code 121 Sealed: IADC Code 124 2. Type H for medium-hard to hard formations: Non-sealed: IADC Code 321 Sealed: IADC Code 324 3.Chisel button type for medium formations: Sealed only: IADC Code 415 4. Conical button type for medium-hard to hard formations: Sealed only: IADC Code 515 5. Ovoid/ogive button type for hard formations: Sealed only: IADC Code 725

Hole Opening

155

3600 M6980 Hole enlarger BoDies fielD repair anD service proceDure
Design Background The 3600 Hole Enlarger cluster-type bodies are made of 4142 alloy bar machined to receive washpipes and flanges. The gussets and flanges are mild steel plates. Typically, cluster-type hole enlarger bodies use 1750 cutters in four to six clusters, with four jets directed to the shelf (a fifth jet is a lift booster pointed upward on 3600). Cutters are mounted on saddles which are composed of upper arm (1750 arm), lower arm and bushing. Cutters are radially positioned to a predetermined gauge diameter. Cutters on the same gauge diameter are positioned at the same height from the flange. Cross lock pins hold cutters to saddles. Two types are in use: 1. Solid retained by short concentric spring pins for button cutters in hard formation jobs. 2. Concentric spring pins. It is the intent of the design that the saddles are the major replaceable components of the body. Inspection After each run and prior to a new run, inspect the overall tool condition. If cutter will be rerun make sure: 1. All pins/lock pins are secure. 2. No indication of damage to the cutters or body (tool joints, jets, body welds, necks). 3. Check pilot bit. 4. Wash cutters, air dry and lubricate bearings. 5. Check tool joints by magnetic inspection and thread gauging. If cutters need to be replaced, remove cutters promptly so as to avoid being rust frozen. Wash body and inspect the body for wear on the following areas: Saddle evaluation (the cutter saddle is serviced as a unit). 1. Bushing cam ear wear or damage. 2. Saddle shirttail area pin hole fit to cutter pin tight or at worse no more than 1 64 in. clearance. Cross lock pin hole. No visual damage. No cracks between holes or edges of holes. Shirttail hardfacing is not worn.

156

Hole Opening

cHanging cutter asseMBlies

Removal of Old Assembly 1. Wash hole enlarger thoroughly when removing from the hole. 2. Unlock the eccentric cam locking segment by turning slightly in the direction of the drillstring rotation, using the driving bar and hammer (See photo A, page 157). 3. Drive out the lock pin using drift pin and a hammer (See photo B, page 157). 4. Screw puller assembly into cutter pin (See photo C, page 157). Force cutter pin out with several sharp thrusts of the sliding knocker (See photo D, page 157). 5. Slide and/or pry out the used cutter. 6. Inspect circulation jet, bushing, snap ring and O-ring. If necessary, replace these parts. 7. Clean body surfaces adjacent to cutter and cutter pin hole. Installing New Assembly 1. Set the new cutter assembly in the pocket with the flat in the locking segment toward the bottom end of the body. 2. Adjust the locking segment until the pin holes in the cutter and arm are in alignment. 3. Screw pin assembly wrench into cutter pin and insert to bottom of pocket, rotating slowly until lock pin slot in the cutter pin lines up with the lock pin hole in the cutter arm. 4. Drive in outer lock pin with hammer. Then the inner lock is driven inside the outer lock pin. 5. Unscrew and remove pin assembly wrench. 6. The eccentric cam locking segment will now be in the relaxed position. The cam will automatically lock itself with cutter rotation. Arm Replacement The Model 6980 hole enlarger is machined from a high-quality alloy steel and heat treated to metallurgical standards. Occasionally cutter arms may have to be replaced. New cutter arms, reusable welding fixtures and complete instructions are available for this type of repair. Contact a local Smith Services representative.

Hole Opening

157

A. Eccentric cam is loosened by driving segment in direction of drillstring rotation.

B. Locking pin is driven out through the side of the cutter arm.

C. Pin puller assembly is screwed into cutter pin and tightened.

D. Cutter pin is removed by jarring upward with several sharp thrusts of knocker.

158 Hole Enlarger Specifications

Size No. Enlarging Range From To Min. Pilot Hole Size Dia. Reqd. 47 412 578 518 512 67 612 714 758 734 97 914 914
1014 1014 1114 1234 1334 1134 1234 1334 1434 1578 1712 1712

Hole Opening

Upper Neck Dia.(s)

Upper Lower Neck Pilot Length Dia.(s)

Lower No. of Body Assy. Wt. Cutter Neck Cutters w/Cutters (lb.) Assy. Wt. Length Per Set (lb.)

0625 0675 0787 0862 0900 0950 0987 1062 1100 1250 1375 1400 1550 1650 1750 1850 2000 2100 2200 2300 2400 2500 2600 *3000 *3600

67 612 612 838 834 914 958 1012 1078 1078 1078 1078 1434
1534 1534 1534 1534 1534 1534 1534 1534 1534 1534 1534 1534

1612 1712 1812 2078 2178 2278 2378 2478 2578 2678 3078 3678

614 634 778 858 9 912 978 1058 11 1214 1312 1334 1512

434 434 534 534 534 534 - 734 534 - 734 734 - 814 734 - 814 734 - 814 734 - 814 734 - 814 734 - 10
734 - 9 734 - 10 734 - 10 734 - 10 734 - 10 734 - 10 734 - 10 734 - 10 734 - 10 734 - 10 9 - 10 9 - 10

36 36 36 36 36 36 36 36 36 36 36 36 36
36 36 36 36 36 36 36 36 36 36 36 36

734 - 9 734 - 10 734 - 10 734 - 10 734 - 10 734 - 10 734 - 10 734 - 10 734 - 10 734 - 10 9 - 10 9 - 10

314 314 412 414 414 414 414 512 512 512 512 734 734 - 10

15 15 15 15 15 15 15 15 15 15 15 15 15
15 15 15 15 15 15 15 15 15 15 15 15

3 5 3 3 3 3 3 3 3 3 3 3 3
3 3 3 3 3 3 3 3 3 3 4 6

915 - 1,075 995 - 1,155 1,075 - 1,235 1,245 - 1,405 1,260 - 1,420 1,445 - 1,605 1,645 - 1,805 1,845 - 2,005 1,895 - 2,055 1,945 - 2,105 2,095 - 2,255 2,405 - 2,565

200 - 230 220 - 250 270 - 300 280 - 310 285 - 315 295 - 325 310 - 440 400 - 490 405 - 600 490 - 690 670 - 830 680 - 840 835 - 995

8 10 14 16 16 23 35 35 35 55 55 55 100

100 155 155 155 155 235 235 235 235 425 205 310

*Over 2600 cluster arm-type construction. Available on special order only. Notes: 1. All dimensions are given in inches unless otherwise stated. 2. All weights are approximate. Ordering Instructions: When ordering or requesting quotations please specify: 1. Body type: standard or directional type; if directional type, specify round or sidehill

bullnose, or extra-long stinger. Also specify whether it is to be solid or if circulation through bullnose or stinger is required. 2. Body size number, pilot hole size and enlarged hole size 3. Upper and lower neck diameters and connection sizes 4. If tool is to be dressed and cutter type desired

Well Abandonment

159

Well AbAndonment - GenerAl InformAtIon

Well abandonment is a specialized art. It requires experienced personnel who can handle any kind of equipment, on any kind of rig, in any type of situation, as well as the right type of equipment. Smith well abandonment professionals are available worldwide to perform these critical services with the excellent tools we describe below.

Shortcut 97/8 In. cut & Pull ASSembly WIth SeAl ASSembly retrIevInG tool
Assembly ydraulic casing cutter H igh torque low speed mud motor H ix ft. stroke bumper jar S pear S 8 in. stroke bumper jar 1 rill collar, two stands minimum D rill pipe space out D eal assembly retrieving tool S rill pipe to surface D Note: Allow for enough space out to strip seal assembly to riser. Procedure IH until seal assembly retrieving tool is above seal. T Note: Go on compensator before landing out with retrievable tool. ngage seal assembly with retrieving tool. E ull seal assembly and strip up into riser. P pot casing cutter at desired cutting depth. S pply slight left-hand torque to engage spear (one-quarter turn). A ull enough overpull to allow for compensation. P tart pump and slowly increase flow rate to proper gallons per S minute to run motor and cut casing. fter casing cut is achieved slack off to string weight. A otate one-quarter turn to the right to disengage spear. R ull out of hole until spear is just below well head. P pply left-hand torque engaging spear. A ull out of hole with casing. P ay out seal assembly and retrieving tool at surface. L ull out of hole until casing hanger is landed out on rotary table. P Note: Space out so spear assembly can be racked in derrick.

160

Well Abandonment isengage spear. D ack back in derrick. R ig up, lay down casing. R Note: We will need estimated mud weight that will be used to cut casings with motor before job ships to run hydraulics and properly jet tools. Shortcut Cut & Pull Assembly
Bumper sub

Shortcut Plug & Abandonment System Spear Specifications

OD (in.) ID (in.) Overall Length (in.) Tool Joint Connection (in.) Tensile Yield - Slips Engaged (lbf.) Tensile Yield - Lugs Engaged (lbf.) Torsional Yield - Lugs Engaged (lbf-ft.) Torsional Yield - Mandrel (lbf-ft.) Estimated Tensile Drag from Friction Blocks (lbf.) Estimated Torsional Drag from Friction Blocks (lbf-ft.) 8 21 4 126 41 2 IF 1,500,000 200,000 40,000 61,000 1,000 <500

HydraStroke

Shortcut spear

Mud motor

Hydraulic pipe cutter

Note: The P&A Spear is designed for straight push/pull only. It is not designed as a back-off spear.

The P&A Spear is a special purpose spear for cut & pull operations. The spear allows the operator to enter and slide to a pre-established depth without dragging the slips in the casing. As long as the operator maintains low right-hand torque in the release slot position, the operator can raise and lower the spear without engaging the slips in the casing. Once at depth, the operator can begin low-torque left-hand rotation and slowly pick up to enter into the engagement slot to enter the casing. Once engaged, the operator can pull the casing. The friction blocks maintain a constant drag on the casing that allows the operator to engage the slots by holding the weight of the outer housing.

Well Abandonment

161

PIPe cutterS
Pipe cutters feature tungsten carbide dressed-cutting arms. The arms are expanded into cutting position when actuated by pump pressure. The P-cutter can be equipped with a Flo-Tel device, which signals the operator that a string has been cut through with a sudden drop in pump pressure. This prevents skinning the casing or coming out of the hole before the cut is complete. Pipe cutters are available in three popular sizes with various arm lengths enabling the operator to cut from six to 58 in. diameters. P-cutters can be used to cut concentric or eccentrically hung strings of casing, cemented or not, both quickly and safely. Unlike explosive parting, the P-cutter assures a clean cut. Pipe Cutting Operating Parameters or best results, run arms long enough to cut only one string of F pipe each trip (see page 171). t the point of cut-out, begin rotation at 50 RPM. Typically the A rotary will be 50 to 80 RPM, and when cutting knives encounter casing, there will be a noticeable increase in torque. The difference from free rotating torque will depend upon casing condition, cement integrity, depth and other well conditions. After rotary is established, torque will become more erratic until severed. Once cut through, torque and rotary will smooth out. weight gain is noticed on all cuts following the first string. Slack A off slightly to relieve the hydraulic draw-down of the tool. The result will be faster cutting. ecause of the eccentricity of multiple casing strings, circulation B can be lost after the cut is partially made. This is normal, however, cuttings are still being removed and the cutter arms are being lubricated. t times the P-cutter Flo-Tel action does not show a good pump A pressure drop at the surface because of the shallow depth. However, pump strokes will increase, indicating full cut-out. illing upward with a P-cutter can result in backing off a short M length of the casing above the cutter arms. In the event this happens and cement in the annulus prevents pulling the upper section of the pipe, move the tool up and re-cut above the point of back-off. he most severe torque and noise occurs just prior to the final T parting of the string.

162 Recommended Flow Rates and Rotary Speeds Series No.

5700-V 8200-2 11700-V

Well Abandonment

Begin Cut-out GPM

125 - 175 125 - 175 250 - 450

While Cutting GPM

250 - 300 250 - 325 400 - 600

RPM
50 50 50

RPM
100 - 120 80 - 100 60 - 80

Jack-ups and Submersibles P-cutters are relatively simple to operate on these rigs. The rig is stationary, therefore all vertical changes in depths can be made by the length of kelly used below the rotary bushing. When the cutter reaches the predetermined cutting depth, the rotary is started and brought to the correct RPM to cut that size of casing. The rotary torque should be recorded. Start the pump slowly and bring pressure up to recommended level for the size of cutter used. The rotary torque will increase when pump pressure is applied, and the RPM will usually slow down. Increase rotary to bring the RPM back up to the desired speed. When the torque has more than doubled, this is an indication that the cutter has parted the casing. A typical string would consist of the pipe cutting assembly on bottom, crossover sub and drill pipe. When cutting 133 8 in. and larger casing, a top sub with stabilizer blades should be used. Semi-submersibles and Drill Ships To compensate for the vertical movement of floaters, it is necessary to run the marine support swivel above the pipe cutter assembly as illustrated on page 163. In order to have the cutter at the correct depth, the distance between the landing ring and cutter should be adjusted. It is also necessary to run a long-stroke bumper sub above the marine support swivel. This will allow the cutter to remain at a constant depth while the rig moves up and down. A bumper sub with a six ft. stroke will compensate for the rig movement. It is not necessary to use the bumper sub on those rigs equipped with a motion compensator. Set the motion compensator to allow for 5,000 to 8,000 lb. of weight resting on the landing ring.

Well Abandonment Pipe Cutter Assembly for Floaters The following illustration shows our recommended assembly. Smiths well abandonment systems consist of the marine support swivel, the stabilizer top sub and the pipe cutter. The pipe cutter assembly is located below the marine support swivel in the wellhead. The marine support swivel permits the operator to vertically position the pipe cutter assembly and maintain that position during operation. The stabilizer top sub is used to center the pipe cutter in the casing. Selecting P-Cutter Lengths and Diameters The table below will determine arm length for cutting eccentric pipe. It is recommended to add one to three in. of arm length allowing for extreme eccentric condition. Pipe Cutter Assembly for Floaters

163

Casing head

Marine swivel

30 in. casing

Spacer sub Drill collar or drill pipe

20 in. casing 133 8 in. casing Stabilizer or conventional top sub

Pipe cutter

95 8 in. casing

164

Well Abandonment Calculating Spacer Sub Lengths for P Cutters When cutting multiple strings of casing and using a marine support swivel as a landing device, it is necessary to use shorter spacer subs as the length of the arm increases. This allows the new arm to enter the window in casing already cut. The formula shown below determines the length of sub required for the next run using a longer set of arms. LR = LU (dr du + 1) Where: LR = Required sub length for next run LU = Length of sub used on last run dr = rm length from center of pin hole to cutter tip required for A next run du = rm length from center of pin hole to cutter tip used on A last run Examples of Spacer Sub Length Sizing Given: LU = 33 in. Arm opening sizes required are 12, 16 and 24 in. The required sub lengths are 33 in. (12 in. opening), 30 in. (16 in. opening) and 24 in. (24 in. opening). Spacer Sub Length Sizing Arm Opening Size (in.)
12 16 24

Arm Length (d)

41 4 6 2
1

dr du + 1
3 4
1

LU
33 33 30

LR
30 24

111 4

53 4

Note: Tolerances of 14 in. on sub length are acceptable.

Well Abandonment Spacer Sub Arrangement

165

Drillstring

LU

Spacer sub

LR

du Pipe cutter Short arms 1st cut Long arms 2nd cut

dr

166

Well Abandonment Selecting P-Cutter Lengths and Diameters The table below will determine arm length for cutting eccentric pipe. It is recommended to add one to three in. of arm length allowing for extreme eccentric condition. Eccentric Diameters (dimensions shown in inches) Casing Combinations Size A
195 8 19 8
5

Size B
133 8 13 8
3

Size C
20 24 20 24 26 20 24 26 26 30 36 30 36

Eccentric Dia.
27.881 34.839 27.916 34.874 38.874 26.791 33.749 37.749 34.915 42.915 54.915 43.873 55.873

Casing Combinations Size A

133 8 13 8
3

Size B
26 26 20 20 20 24 24 26 26 24 24 26 26

Size C
30 36 26 30 36 30 36 30 36 30 36 30 36

Eccentric Dia.
49.873 55.873 32.290 40.290 52.290 41.248 53.248 41.248 53.248 37.248 49.248 37.248 49.248

195 8 19 8
5

163 8 16 8
3

163 8 16 8
3

195 8 10 4
3

163 8 16 8
3

163 8 16 8
3

103 4 10 4
3

163 8 16 8
3

163 8 16 8
3

133 8 133 8 13 8
3

203 8 203 8 20 8
3

163 8 203 8 20 8
3

133 8 13 8
3

243 8 24 8
3

203 8 20 8
3

For combination of casings not listed in the preceding table, the eccentric diameter can be calculated by the following formula: DECC = DBID + DCID + DCCOUP. DACOUP. DBCOUP. Example of Arm Size Selection Casing A: 95 8 in., Casing B: 133 8 in., Casing C: 20 in. Eccentric diameter: 28 in. Cutter arm opening diameter: 29 to 31 in.

Well Abandonment Eccentric Diameters

167

Casing C Casing B Casing A

Tool and casing A C L

DACOUP. = Coupling diameter of A DBID = ID of casing B DBCOUP. = Coupling diameter of B DCID = ID of casing C

DCCOUP. = Coupling diameter of C DECC = Eccentric diameter

168 Pipe Cutter Components

Well Abandonment

Stabilizer (optional)

Body

Piston spring Piston packing Piston Hinge pin

Cutter arm

Well Abandonment Pipe Cutter Disassembly 1. Remove hinge pin retainer screws. 2. Remove hinge pins. 3. Remove cutter arms. 4. Remove Flo-Tel snap ring, if applicable. 5. Remove Flo-Tel, if applicable. 6. Remove piston. Remove and inspect piston packing. 7. Remove piston spring and piston stop ring. Servicing The tool should be disassembled and thoroughly cleaned after the completion of each job. Steam cleaning is preferred; however, when facilities are not available, cleaning solvents may be used. The piston packing should be inspected after cleaning and replaced if any wear is visible. It is essential for proper performance that the V-type lips face the top of the tool. Note: Before the tool is reassembled, all parts should be thoroughly lubricated. Any type of light grease is suitable. Assembly 1. Replace piston spring and stop ring. 2. Replace piston. 3. Replace Flo-Tel, if applicable. 4. Replace Flo-Tel snap ring, if applicable. 5. eplace cutter arms, hinge pins and hinge R pin retaining screws.

169

170 Pipe Cutter

Fishing neck diameter Top pin connection

Well Abandonment

Fishing neck length

(Shown with optional stabilizer)

Ordering Instructions: When ordering or requesting quotations on pipe cutters, please specify: 1. ool series T 2. Standard or stabilizer top sub 3. ishing neck diameter F 4. ize(s) and weight(s) of casing S to be cut 5. ype of rig (drillship, semi, T jack-up, etc.) 6. f known, specify whether casI ing is concentric or eccentric and whether it is cemented

Body diameter Maximum cutting diameter

Well Abandonment Specifications

Stabilizer Top Sub Standard Top Sub* Tool Body Top Pin Cutting Dia. Series Dia. Conn. API Reg. Min. Max. Fishing Fishing Overall Wt. Fishing Overall Wt. ID OD Neck Neck Length (lb.) Neck Length (lb.) Length Dia. Length
5700-V 153 4 31 2 16 25 48 58 43 4 8 8 - 9 18 18 20 70 89 107 350 925 1,885

171

8200-2 181 4 65 8 181 2 11700-V 113 4 65 8, 75 8 121 2

Removable stabilizers for 75 8 in. casing are included with pipe cutter 18 115 1,400 32 134 2,400

*Recommended when using 133 8 in. casing and larger. Notes: 1. All dimensions are given in inches unless otherwise stated. 2. All weights are approximate. 3. Includes tool and top sub.

Recommended Stabilizer Blade Diameters Casing Size

133 8 1638 2038

Stabilizer Blade Dia.

123 8 143 4 181 2 2338 2738 3338

2638 3038 3638

Pipe Cutter Arms Specifications Tool Series Body Dia.

5700-V

Blade Length
1614 1014 1214 1714

Max. Exp. Dia.

101 2 143 4 213 4 251 4 121 4 1914 2614 3814 491 2

131 2

153 4

131 2
101 2 161 2 221 4

8200-2

18 4
1

161 4

171 2 1014 1614 2014 2214

3514 413 4 451 4 5214 5914

241 2

11700-V

113 4

2614 3014

Note: All dimensions are given in inches unless otherwise stated.

172

Well Abandonment

cASInG bAck-off tool

The Casing Back-off Tool facilitates back-off of uncemented casing stumps at a selected coupling location downhole after a section has been cut and retrieved. This process can effectively be achieved in vertical or horizontal wells. The tool features nine sub-assemblies, including two hydraulic anchors and a torque generator. The hydraulic anchors allow the Back-off Tool to be used in horizontal wells because drill collar weight is not required to hold the anchors open. The tool is cycled, and using hydraulic pressure only, the torque generator and anchors work in tandem to breakout and unscrew the casing threaded connectors with approximately one-half turn per cycle. When connection torque is sufficiently lowered, the Back-off Tool is pulled out of the hole, and a casing spear is run to complete the unscrewing and recovery of the casing stump. A threaded connection remains downhole for the new casing string to be stabbed into and made up. Smith Services can also supply subs for aligning the old and new casing strings to facilitate proper make-up downhole. Features and Benefits ydraulic anchor eliminates need for drill collar weight to achieve H back-off, making the system ideal for horizontal wells. apable of generating up to 60,000 ft-lbs. of torque. C eaves a threaded connection for re-engaging new casing string L after worn casing is removed. aintains original casing strength and integrity. M liminates reduced casing drift diameter resulting from internal E casing patches. liminates left-hand drill pipe E liminates need for overtorquing connections in a left-hand work E string on a blind back-off from surface. Applications eplacing worn or damaged sections of casing by unscrewing R uncemented casing at a selected coupling location after it has been cut and retrieved, in vertical or horizontal wells

Well Abandonment Casing Back-Off Tool

173

174

Well Abandonment

mArIne SuPPort SWIvel

The marine support swivel design allows free and full rotation of tools while preventing vertical movement and allows for full circulation downhole. The bearing design will withstand the most severe thrust and radial loads encountered during cutting operations. Marine Support Swivel Disassembly 1. Remove socket head cap screws and seating plate. 2. emove all socket head cap screws and bottom retaining plate. R 3. heck the O-ring and the packings in the bottom retainer plate. C 4. emove all socket head cap screws and two socket set screws R from the top retaining plate. 5. heck the O-ring and the packings in the top retainer plate. C 6. Slide the bearing housing off the top of mandrel. 7. Remove thrust bearing. 8. Remove both radial bearing and bearing spacer. Servicing The tool should be thoroughly cleaned after the completion of each job. Steam cleaning is the preferred method. However, where these facilities are not available, cleaning solvent can be used. All packings and O-rings should be inspected after cleaning and replaced if any wear is visible. After these parts have been cleaned with solvent, they must be lubricated with anti-galling compound. All bearings must be packed with grease. All rotary shouldered connections must be lubricated with a thread compound. Assembly 1. lide radial bearing, bearing spacer and second radial bearing S from the top end of mandrel into position. 2. Slide thrust bearing from the bottom end of mandrel. 3. Slide bearing housing over the mandrel. 4. Install all packings and O-rings. 5. eplace the top retaining plate packings, making sure the V-type R lips of the packing face up. Replace O-ring. 6. Slide top retaining plate into place, secure with cap screws. 7. Replace two thread protector set screws. 8. Install seating plate and secure in place with screws. 9. ill bearing housing with S.A.E. 90-weight oil or equivalent. Install F grease fitting and relief valve. 10. heck for leakage after plugs are installed, and smooth turning of C the bearing housing assembly over the mandrel.

Well Abandonment Marine Support Swivel

ID bore diameter Bearing housing diameter

175

Fishing neck diameter

Fishing neck length

Seating plate diameter

Bottom pin connection OD bottom neck diameter

176 Specifications
Tool Bearing Std. Seating Series House Plate Dia. Dia.
6200-2 121 4 135 8 or 143 8 143 8, 24, 30

Well Abandonment

Fishing Fishing Bottom Top and Overall Neck Neck Bottom Length Neck Conn. Dia. Length Dia. API Reg.
61 4 73 4 or 8 36 36 61 4 73 4 41 2 IF 65 8 Reg. 78 82

Bore

Wt. (lb.)

213 16 213 16

850 1,300

7700-2 1315 16

Notes: 1. ll dimensions are given in inches unless otherwise stated. A 2. ll weights are approximate. A Ordering Instructions: When ordering or requesting quotations on the marine support swivel, please specify the seating plate diameter, or make and model of subsea casing head.

Well Abandonment

177

the duAl PluG And AbAndonment SyStem only SmIth hAS It

Mechanical Cutting vs. Explosive Severing Thousands of plug and abandonment jobs have shown us that they can both be the best way. If you are trying to decide which method is best suited to your particular plug and abandonment requirements, it makes good sense to talk to the one company that can offer you either or both services anywhere in the world. We have been saving operators time and money on offshore plug and abandonment jobs for more than 25 years, so we feel qualified to recommend the combination that is right for your well. One-trip Cut and Recovery Features educes rig operation time because spear and casing cutter are run R in the same trip. umper ring rests on casing hanger so that spear grapple and outer B housing remain stationary in the casing hanger during rotation of the cutting string, thus reducing the possibility of damage. nique grapple design eliminates grapple damage to wellhead. U Rugged three-blade cutter design cuts fast. utter arms expand up to five times the tool diameter and achieve C maximum stability under adverse cutting conditions such as hard spots, eccentricity and interrupted cuts. rms retracted by stopping circulation and picking up drillstring. A ptional patented Tension Cut and Recovery System cuts faster O because casing is held in tension rather than compression.

178 Dual Plug and Abandonment System

Well Abandonment

Well Abandonment Wellhead Severing System

179

180

Well Abandonment

dynA-cut deePWAter WellheAd SeverInG SyStem

Features atented Deepwater Wellhead Severing System operable in water P depths beyond 10,000 ft. One-trip sever and retrieve operation. Severs multiple strings of casing. Used in pipe sizes seven in. or larger. educes rig-up and running time because electrical cable R is eliminated. lectrical power to fire charge removed from charge except when E detonation is desired. lectrical power conveyed to charge by dropping unit through E drill pipe or by running unit on slickline or sandline. emovable power source permits safe recovery of downhole R charge should a malfunction occur. ackup method of downhole disconnection provides additional B protection should retrieval of power source be necessary. hallow water system using cable-fired detonation is also available. S The Dyna-Cut Wellhead Severing System charge is stored in separate containers as a flammable liquid (nitromethane) and as a corrosive acid (diethylenetriamine). Both are biodegradable and are not explosive until combined in the proper percentages by a Smith technician. The Exploding Bridge Wire (EBW) detonators contain no primary explosives and can only be actuated by the power unit. Since the detonators cannot be actuated by extraneous sources such as radio signals, the rig can maintain full communication throughout the operation. The unarmed charge is run into the hole on drill pipe and armed only after it is safely positioned below the wellhead.

Reference Tables API Casing Data Casing OD Casing Specifications Coupling Wt. with OD Coupling (lb/ft.)
5.000 9.50 11.60 13.50 11.50 13.00 15.00 18.00 13.00 14.00 15.50 17.00 20.00 23.00 15.00 18.00 20.00 23.00 17.00 20.00 24.00 28.00 32.00 17.00 20.00 23.00 26.00 29.00 32.00 35.00 38.00 20.00 24.00 26.40 29.70 33.70 39.00

181

Drift ID Casing ID
4.090 4.000 3.920 4.560 4.494 4.408 4.276 5.044 5.012 4.950 4.892 4.778 4.670 5.524 5.424 5.352 5.240 6.135 6.049 5.921 5.791 5.675 6.538 6.456 6.366 6.276 6.184 6.094 6.004 5.920 7.125 7.025 6.969 6.875 6.765 6.625 3.965 3.875 3.795 4.435 4.369 4.283 4.151 4.919 4.887 4.825 4.767 4.653 4.545 5.399 5.299 5.227 5.115 6.010 5.924 5.796 5.666 5.550 6.413 6.331 6.241 6.151 6.059 5.969 5.879 5.795 7.000 6.900 6.844 6.750 6.640 6.500

Bit Size

4 2
1

5.563

51 2

6.050

6.625

65 8

7.390

7.656

75 8

8.500

37 8 37 8 33 4 41 4 41 4 41 4 41 8 43 4 43 4 43 4 43 4 45 8 41 2 43 4 43 4 43 4 43 4 6 57 8 55 8 55 8 55 8 61 4 61 4 61 4 61 8 6 6 57 8 53 4 63 4 63 4 63 4 63 4 65 8 61 4

Note: All dimensions are given in inches unless otherwise stated.

182 API Casing Data (continued) Casing Specifications Casing OD Coupling Wt. with OD Coupling (lb/ft.)
24.00 28.00 32.00 36.00 40.00 44.00 49.00 29.30 32.30 36.00 40.00 43.50 47.00 53.50 32.75 40.50 45.50 51.00 55.50 60.70 65.70 38.00 42.00 47.00 54.00 60.00 48.00 54.50 61.00 68.00 72.00 55.00 65.00 75.00 84.00 94.00 106.50 133.00

Reference Tables

Drift ID Casing ID
8.097 8.017 7.921 7.825 7.725 7.625 7.511 9.063 9.001 8.921 8.835 8.755 8.681 8.535 10.192 10.050 9.950 9.850 9.760 9.660 9.560 11.150 11.084 11.000 10.880 10.772 12.715 12.615 12.515 12.415 12.347 15.376 15.250 15.124 15.010 19.124 19.000 18.730 7.972 7.892 7.796 7.700 7.600 7.500 7.386 8.907 8.845 8.765 8.679 8.599 8.525 8.379 10.036 9.894 9.794 9.694 9.604 9.504 9.404 10.994 10.928 10.844 10.724 10.616 12.559 12.459 12.359 12.259 12.191 15.188 15.062 14.936 14.822 18.936 18.812 18.542

Bit Size

85 8

9.625

77 8 77 8 75 8 75 8 75 8 73 8 73 8 83 4 83 4 83 4 85 8 85 8 81 2 83 8 97 8 97 8 93 4 95 8 95 8 91 2 91 2 113 8 103 4 103 4 105 8 105 8 121 4 121 4 121 4 121 4 123 8 153 8 153 8 143 4 143 4 171 2 171 2 171 2

95 8

10.625

103 4

11.750

113 4

12.750

133 8

14.375

163 8

17.000

203 8

21.000

Reference Tables Rock Bit Comparison Chart Maximum Cone Dimensions for Three-cone Rock Bits Size Max. Max. Range Dia. Length. in. mm in. mm in. mm
31 2 137 8 143 4 157 8 161 4 161 2 163 4 173 8 181 8 181 8 181 2 185 8 191 8 191 8 191 2 195 8 197 8 101 8 105 8 111 8 117 8 121 8 121 4 131 4 151 8 161 8 171 2 181 2 201 8 221 8 241 8 261 8 281 8 189 198 121 149 159 165 172 187 203 206 216 219 229 232 241 245 251 254 270 279 302 305 311 337 381 406 445 470 508 559 610 660 711 23 8 27 8 41 4 41 2 51 4 57 8 61 8 61 2 63 4 71 4 77 8 81 8 95 8 101 4 111 2 121 8 121 2 133 4 151 4 161 8 171 8 60 73 108 114 133 149 156 165 171 184 200 203 244 260 292 305 318 349 387 406 432 15 8 21 8 31 8 31 2 41 8 41 8 45 8 43 8 43 4 51 2 57 8 61 8 75 8 81 8 85 8 91 8 95 8 101 2 111 4 123 4 131 8 41 54 79 89 102 105 117 111 121 140 149 156 194 206 219 229 244 267 286 324 330

183

Milled Tooth lb. kg

10 15 35 45 75 90 95 125 135 165 195 205 345 410 515 525 625 1,000 1,385 1,450 1,550 5 7 16 20 34 41 43 57 61 75 89 93 157 186 234 239 284 455 629 659 704

TCI Wt. lb.

12 20 45 55 85 95 100 130 145 175 210 225 380 450 545 570 700 1,170 1,400 1,550 1,650

kg
5 9 20 25 39 43 45 59 66 80 95 102 173 205 248 259 318 532 636 704 750

184 Recommended Rock Bit Make-up Torque Size Range API Pin Size in. mm in. mm
4 8 5 51 8 73 8 758 9
5

Reference Tables

Recommended Make-up Torque ft/lb. Nm

3,000 13,500 6,000 17,000 7,000 19,000 12,000 16,000 28,000 32,000 34,000 40,000 4,000 14,800 8,000 19,500 9,500 12,000 16,000 22,000 38,000 43,000 46,000 54,000

31 2 41 2

89 114 118 127 137 187 194 229 241 711 375 711

23 8 Reg. 27 8 Reg. 31 2 Reg. 41 2 Reg. 65 8 Reg. 6 8 Reg. or 75 8 Reg.

5

60 73 89 114 168 168 or 194 194 or 219

14 4 28*
3

91 2 28*

181 2 28*

470 711

75 8 Reg. or 85 8 Reg.

40,000 60,000

54,000 81,000

*Make-up torque must correspond to API pin connection for each bit size. Note: Some of the above bit sizes are available with alternate pin connections on special order.

Reference Tables Nozzle Types and Applications for Smith Bits Milled Tooth Series Bit Size (in.)
131 2 143 4 157 8 163 4 17 8 17 8
3 5

185

Jet/Air Series Journal Bearing

55 70 95

Open Bearing Sealed Bearing

Open Bearing

65 95 95 95 95 95 100 100 100 95 95 95 95 100 100 100

177 8 183 8 18 2 18 4
1 3

95 95 95 95 100 100 100

95 95 95 95

191 2 197 8 10 8 12 4
5 1

131 2 143 4 161 2 171 2 20 2 28 2

1 1

Nozzle Types and Applications for Smith Bits (cont.) TCI Series Bit Size (in.) A1, Twocone Outer Jets Sealed/ Journal Bearing
55 70 95 75 75 100 100 100 95 95 95 95 100 100 65 70 95 95 95 95 95/100 65 70 70 95 97 97 97 97/98 105 105 105 98 98 98 98 105 105 105

All Three-Cone Bits Full Center Jets Ext. Nozzles Mini Jets MT TCI

131 2 143 4 157 8 163 4 17 8 17 8

3 5

177 8 183 8 18 2 18 4
1 3

191 2 197 8 10 8 12 4
5 1

131 2 143 4 161 2 171 2 201 2 281 2

186

Rock Bit Comparison Chart

4. Sealed Roller Bearing
Security S3SJ SDS ATX1 GTX1 S11 S33S MSDSH ATXG1 SS33S MSDSSH MAXG1 MS33S MSDSHOD MAXGT1 S33 ATX3 GTX3 M44N S21G MS21G S31G H77SG S44 S13G MS13G S33G SS33G S44G SS44G M44NG MM44NG MS11G S33SG SS33SG Smith Hughes Reed Security Smith Hughes Reed Security

Milled Tooth

1. Standard Roller Bearing

5. Sealed Roller Bearing Gauge Protected

Series

Types

Formations

Smith

Hughes

Reed

DSJ

R1

Y11

Soft Formations/ Low-compressive Strength S3J S3TJ

DTJ

R2

Y12

DGJ

R3

Y13

1 M4 H7 H7J H77

V2J

R4

S4J S4T S4TJ M4NJ

Medium to MediumHard Formations/ High-compressive Strength

2 3 1

DR5

SDGH ATXG3 MSDGH MAXG3 MSDGHOD MAXGT3 SVH MSVH

R7

Hard, Semi-abrasive Formations

2 3 4

Reference Tables

Rock Bit Comparison Chart (continued)

7. Sealed Friction Bearing Gauge Protected
Security S33SF MHP11G S33SGF Smith Hughes Reed Security

Milled Tooth

6. Sealed Friction Bearing

Series

Types

Formations

Smith

Hughes

Reed

Reference Tables

FDS FDS+ FDSS+ S33F S44F M44NF JG4 HP21G M44NGF FDGH MFDGH MFDGHOD FVH JG3 ATMG3 HP13G MHP13G

ATJ1, GT1 ATJ1S ATM1 ATM1S

HP11 HP11+

Soft Formations/ Low-compressive Strength S33GF S33TGF SS33GF S44GF

FDT

ATJ2

HP12 EHP12

MFDSH ATMG1 MFDSSH ATMG1S MFDSHOD ATJG1H ATMGT1 GTG1 JG2

FDG

J3

FV

J4

2 H77F H77SGF JG7 HP31G

Medium to MediumHard Formations/ High-compressive Strength

2 3 1

3 JG8

Hard, Semi-abrasive Formations

2 3 4

187

188

Rock Bit Comparison Chart (continued)

5. Sealed Roller Bearing Gauge Protected
Security M01S MAX00 M01SOD MAXGT00 M02S GTX03 M02SOD MAX03 MAXGT03 ATX05 MAX05 SS81 S43A MS43A S82 SS82 F1 MF1 F1OD MF10D F05 MS41A SS80 MF02 ATJ00 EHP41A ATM00 GT00 EHP41H ATMGT00 GT03 ATMGT03 ATJ05 ATM05 ATJ05C S81F S82F SS82F S82CF HZS82F S80F Smith Hughes Reed Security Smith Hughes Reed Security

TCI

2. Roller Bearing Air Cooled

7. Sealed Friction Bearing Gauge Protected

Series

Soft Formations/ Low-compressive Strength ATM05C GT03C GTX09 MAX09 MAXGT09 ATX11 MAX11 ATX11H MAX11H ATX11C S44A MS44A SS83

Types

Formations

Smith

Hughes

Reed

M05S MF05 F07 M1S M1SOD

15JS M15S M15SD M15SOD

ATJ11 HP43 ATM11 ATJ11S HP43A ATM11HG EHP43A GT09 HP43H ATMGT09 EHP43H ATJ11H ATM11H F15, F15D ATJ11C HP44A F15OD, MF15 ATM11C MA15, MF15D ATM11CG MF15OD GT09C

S83F SS83F

Reference Tables

Rock Bit Comparison Chart (continued)

5. Sealed Roller Bearing Gauge Protected
Security Smith ATX22 MAX22 GTX18, MAXGT18 S84 SS84 A1JSL MA1SL 2JS M2S M2SD S51A MS51A 2SS82 S84F SS84F S84CF DS84F HZS84F 2S82F SS84FD S85F S85CF Hughes Reed Security Smith Hughes Reed Security

TCI

2. Roller Bearing Air Cooled 7. Sealed Friction Bearing Gauge Protected

Series

Types

Formations

Smith

Hughes

Reed

Reference Tables

5 M27S M27SD 3JS M3S M3SOD ATX33A ATX33 S53A S86 SS86 ATX22C S52A SS85

Soft to Mediumhard Formations/ Low-compressive Strength

S86F SS86F S86CF

4 ATX33C S88 GS88 SS88C

S8JA

A1, F15H ATJ22 HP51 F2, F2H ATM22 HP51A F17, F25 ATM18 HP51H F25A ATMGT18 HP51X MF2, F2D GT18 EHP51A MF2D ATMGT20 EHP51H ATJ22S HP51XM ATM22G F27 ATJ22C HP52 F271 ATM22C HP52A MF27 GT18C HP52X MF27D ATM28 F3, MF3 ATJ33 HP53 MF3D ATM33 EHP53 F3H ATJ33A HP53A MF3H ATJ33S EHP53A F3D ATJ35 HP53AM MF30D F35 ATJ33C HP54 F35A ATM33C F37, MF37 ATJ35C F37A F37D MF37D

S88F S88FA S88CF S88CFH

189

190

Rock Bit Comparison Chart (continued)

5. Sealed Roller Bearing Gauge Protected
Security Smith 4JS ATX44 M84 ATJ44 ATJ44A HP61 EHP61 HP61A EHP61A M84F M84FA M84CF Hughes Reed Security Smith Hughes Reed Security

TCI

2. Roller Bearing Air Cooled 7. Sealed Friction Bearing Gauge Protected

Series

Types

Formations

Smith

Hughes

Reed

4GA

G44

6 47JS

Medium-hard Formations/ High-compressive Strength M8JA 5JS ATX44C S62A ATJ44C M88 GM88 M89T HP62 EHP62 HP62A EHP62A HP63 EHP63

5GA

Y62JA

47JA

M85F M88F M88FA M89TF M89F M90F

3 ATJ55 ATJ55A ATJ55R ATJ66 ATJ77 ATJ88 F9 ATJ99 ATJ99A

G55

Y63JA

F4, F4H F4A F45A F45H F47, F47A F47H, F5 F5OD MF5 MF5D F57, F57A F57D, F57OD F57DD F67OD F7, F7OD MF7 F8OD, F8DD HP73 EHP73 H87F H88F H99F HP83 EHP83 H100F

7 H8JA H9JA H88 H100 HH100 H10JA

Hard, Semi-abrasive and Abrasive Formations

4 1 2 3

7GA

G77

Y73JA

Extremely Hard and Abrasive Formations

4 1 2 3

9JA

G99

Y83JA

Reference Tables

Reference Tables Smith Bits Drill Bit Nomenclature

Prefixes F M S A C D = Journal (pfinodal) bearing = Steerable-motor bit bearing = Sealed roller bearing = Designed for air applications = Center jet = Diamond-enhanced gauge inserts TCI Cutting Structure Designations 01 = Very soft formation chisel crest cutting structure 02 = Very soft formation chisel crest cutting structure 05 = Very soft formation chisel crest cutting structure 07 = Soft formation conical cutting structure 1 = Soft formation chisel crest cutting structure

191

Suffixes

DD = Fully diamond-enhanced cutting structure E G H = Full-extended nozzles = Super D-Gun coating = Heel inserts on milled tooth bits. Different, high wear-resistant grade of carbide on TCI bits for abrasive formations = Lug pads = Nominal gauge diameter = Carbide compact in the leg back = Flow Plus extended nozzles = SRT inserts pressed in leg for stabilization = Sealed roller bearing

15 = Soft-medium formation chisel crest cutting structure 17 = Soft-medium formation conical cutting structure 2 = Soft-medium formation chisel crest cutting structure

L N P Q R S

25 = Medium formation chisel crest cutting structure 27 = Medium formation conical cutting structure 3 = Medium formation chisel crest cutting structure

OD = Diamond-enhanced heel row inserts PD = Diamond SRT in the back of the leg

35 = Medium formation chisel crest cutting structure 37 = Medium formation conical cutting structure 4 = Medium formation chisel crest cutting structure

Milled Tooth Cutting Structure Designations DS = Very soft formation cutting structure DT = Soft formation cutting structure DG = Medium formation cutting structure V = Medium-hard formation cutting structure

45 = Medium-hard formation chisel crest cutting structure 47 = Medium-hard formation conical cutting structure 5 = Medium-hard formation chisel crest cutting structure

57 = Medium-hard formation conical cutting structure 67 = Hard formation conical cutting structure 7 8 9 = Hard formation conical cutting structure = Hard formation conical cutting structure = Hard formation conical cutting structure

192

IADC Dull Bit Grading

Cutting Structure Outer Dull Char. 2 3 Location 4 Location (4)
Roller Cone N - Nose Row M - Middle Row G - Gauge Row A - All Rows Cone # 1 2 3 Fixed Cutter C - Cone N - Nose T - Taper S - Shoulder G - Gauge A - All Areas Measure to nearest 1/16 of an in. I - In Gauge 1 - 1/16" Out of Gauge 2 - 2/16" Out of Gauge 4 - 4/16" Out of Gauge

Inner Cutting Structure (1) (All Inner Rows) Bearings/ Seals 5 Gauge 6 Gauge (6) Other Dull Char. 7 Reason Pulled 8

(For fixed cutter bits, use the inner 2/ 3 of the bit radius)

Inner 1

Outer Cutting Structure (2) (Gauge Row Only)

(For fixed cutter bits, use the outer 1/ 3 of the bit radius)

(Use only cutting structure related codes)

Dull Characteristics (3)

Reason Pulled or Run Terminated (8)

In columns 1 and 2 a linear scale from 0 to 8 is used to describe the condition of the cutting structure according to the following:

Steel Tooth Bits A measure of lost tooth height due to abrasion and/or damage 0 - No Loss of Tooth Height 8 - Total Loss of Tooth Height

Insert Bits A measure of total cutting structure reduction due to lost, worn and/or broken inserts 0 - No Lost, Worn and/or Broken Inserts 8 - All Inserts Lost, Worn and/or Broken

Other Dull Characteristics (7) Refer to column 3 codes Bearings/Seals (5)

Cutters *OC - Off Center Wear *PB - Pinched Bit *PN - Plugged Nozzle/ Flow Passage *RG - Rounded Gauge *RO - Ring Out *SD - Shirttail Damage *SS - Self Sharpening Wear *TR - Tracking *WO - Washed Out BIt *WT - Worn Teeth/ Cutters *NO - No Dull Characteristic *Show cone number(s) under location (4) Non-Sealed Bearings A linear scale estimating bearing life used 0 - No Life Used 8 - All Life Used, i.e. no bearing life remaining Sealed Bearings E - Seals Effective F - Seals Failed N - Not Able to Grade X - Fixed Cutter Bit (Bearingless)

Fixed Cutter Bits A measure of lost, worn and/or broken cutting structure 0 - No Lost, Worn and/or Broken Cutting Structure 8 - All of Cutting Structure Lost, Worn and/or Broken

*BC - Broken Cone *BF - Bond Failure *BT - Broken Teeth/ Cutters *BU - Balled Up Bit *CC - Cracked Cone *CD - Cone Dragged *CI - Cone Interference *CR - Cored *CT - Chipped Teeth/ Cutters *ER - Erosion *FC - Flat Crested Wear *HC - Heat Checking *JD - Junk Damage *LC - Lost Cone *LN - Lost Nozzle *LT - Lost Teeth/

BHA - Change Bottom Hole Assembly DMF - Downhole Motor Failure DTF - Downhole Tool Failure DSF - Drillstring Failure DST - Drill Stem Test DP - Drill Plug CM - Condition Mud CP - Core Point FM - Formation Change HP - Hole Problems LIH - Left in Hole HR - Hours on Bit LOG - Run Logs PP - Pump Pressure PR - Penetration Rate RIG - Rig Repair TD - Total Depth/Casing Depth TW - Twist Off TQ - Torque WC - Weather Conditions

Reference Tables

Reference Tables

193

How to Convert wags to swags

Listed on the next five pages are bit selection, bit weight and RPM, hydraulic and drilling fluid property equations for the benefit of other SWAG users. Many should be used with a sprinkling of good judgement and a liberal amount of common sense.

194

Reference Tables A. Bit Selection Equations 1. Cost per foot B + R1 (T1 + t) C1 = 1 F1 2. Breakeven time, at constant rate of penetration B2 + R1 (t) T2 = F C1 1 R1 T1

()

B. Bit Weight-Rotational Speed Equations 1. Drilling rate (soft formation) ROP = kf1 WR

2. Drilling rate (hard formation) ROP = kf1 W1.2 R0.5 3. Bit size vs. penetration rate a. Up to 171 2 in. D ROP2 = ROP1 1 D2 b. 171 2 to 36 in. D ROP2 = ROP1 1 x 1.25 D2 4. Bearing wear constant Hours CB = 100 W x R W 1,000 100 1,000

() ()

5. Tooth wear constant Hours x e(.01 R + .0032 W) CT = 189.2 6. Mechanical horsepower at bit HP = kb Wb1.5 Db2.5 R 7. Bit weight-RPM relationship to bit pressure drop From Fullerton, for (WbR)<250 Pb = 0.678 Dh (WbR)0.5 for 250<(WbR)<350 f o r Pb = 0.044 Dh (WbR) f o r for (WbR)>350 Pb = 0.80 Dh (WbR)0.5

Reference Tables C. Hydraulic Calculation Equations 1. Drill stem bore pressure losses (turbulent flow) a. From Fanning f V2L P = 25.8d b. From Security 0.000061 LQ1.86 P = d4.86 c. From Smith .0000765PV0.18 0.82 Q1.82 L P = d4.82 2. Bit hydraulic horsepower Pb x Q BHHP = 1,714 3. Jet nozzle pressure loss Q2 Pb = 10,858 (An)2 4. Total nozzle area 0.5 Q An = 104.2 Pb 5. Jet velocity 0.32Q Vn = An 6. Jet impact force If = 0.000516 QVn x If = 0.0173Q PBPB x 7. Bottom hole pressure BHP = 0.052 L 8. Bottom hole circulating pressure BHCP = BHP + Pa 9. Annular pressure losses a. From Hagan-Poiseuille for Newtonian laminar flow LV Pa = 1,500 (Dh Dp)2

195

( )

196

Reference Tables C. Hydraulic Calculation Equations (continued) b. From Beck, Nuss and Dunn for plastic laminar flow LYP VLPV Pa = + 225(Dh Dp) 1,500(Dh Dp)2 c. From Fanning for turbulent flow f LV2 Pa = 25.8(Dh Dp) d. From Security for turbulent flow (1.4327 x 10-7) LAV2 Pa = Dh Dp e. From Smith for turbulent flow 0.0000765PV0.18 0.82 Q1.82 L Pa = (Dh Dp)3 (Dh + Dp)1.82 10. Equivalent circulating density BHCP ECD = .052L 11. Reynolds number a. Newtonian fluids 928 Vd Re = M b. Plastic fluids (to determine f) 2,970 Vd Re = PV 12. Average annulus flow velocity 24.5Q AV = (Dh2 Dp2) 13. Annulus critical velocity 1.08PV + 1.08 PV2 + 9.3(Dh Dp)2YP Vc = (Dh Dp) 14. Optimum annular velocity From Fullerton 11,800 AVo = Dh

Reference Tables C. Hydraulic Calculation Equations (continued) 15. Optimum flow rate From Fullerton 482(Dh2 Dp2) Qo = Dh 16. Rock chip slip velocity a. From Stokes for laminar flow, spherical chips 8,310dC2( C ) b. From Pigott for laminar flow, spherical chips 3,226dC2( C ) VS = c. From Rittinger for turbulent flow, spherical chips VS = VS = 155.9 dC(
C

197

d. From Pigott for tubulent flow, flat chips VS = 60.6 dC(

C

17. Effective viscosity a. Viscosity definition S = s Sr b. Bingham Plastic 399 YP (Dh Dp) = PV + AV c. Shear stress, Power Law fluids Ss = kSrn d. Effective viscosity, Power Law e = kSrn1 e. Annular shear rate 2.4 AV Sr = Dh Dp f. Consistency index 511 (YP + PV) k= 511n

198

Reference Tables C. Hydraulic Calculation Equations (continued) g. Power Law Index YP + 2PV n = 3.32 log10 YP + PV 27. Total system losses or pump discharge pressure Pt = Ps + Pc + Pp + Pb + Pca + Ppa

D. Drilling Fluid Property Equations 1. Effects of plastic viscosity ROP2 = ROP1 x 10.003(PV1 PV2) 2. Bentonite clay effects ROP2 = ROP1 x e.051(vol%1 vol%2) 3. Total solids effects ROP2 = ROP1 x 10.0066(vol%1 vol%2) 4. Effects of water loss WL2 + 35 ROP2 = ROP1 x WL1 + 35 5. Oil content effects (vol% oil < 30%) sin(10.6 vol%2 4.83) + 10.33 ROP2 = ROP1 sin(10.6 vol%1 4.83) + 10.33 6. Total drilling fluid effects (density, viscosity, solids, pressure loss) For depths from 8,000 to 12,000 ft.

ROP2 = ROP1e 0.382( 1 2) 7. From Fullerton for density effects log10kf2 = .000208(BHP1 BHP2) + log10kf1

Reference Tables Nomenclature An AV, AVo BHP BHCP BHHP B1, B2 C1 CB Cn CT d Db dc D1, D2 Dh Dp e ECD f F1 k kb kf , kf 1 2 L n PV PV1, PV2
c

199

= = = = = = = = = = = = = = = = = = = = = = = = = = = = = =

Total nozzle area, in.2 Average, optimum annulus velocity, fpm Bottom hole pressure, psi Bottom hole circulating pressure, psi Bit hydraulic horsepower, hp Cost of control, proposed bit, dollars Cost per foot of control bit, dollars/ft. Bearing wearing wear constant Nozzle coefficient, 95 percent Tooth wear constant Inside pipe diameter, in. Bit diameter, in. Chip diameter, in. Smaller, larger bit diameter, in. Hole diameter, in. Outside pipe diameter, in. 2.718 Naperian base Equivalent circulating density, lb/gal. Fanning friction factor Footage drilled, ft. Consistency index Formation factor for horsepower calculation ranging from 4 x 10 5 for very hard to 14 x 10 5 for very soft formations Apparent, corrected formation drillability factor Pipe length or hole depth, ft. Power Law Index Plastic viscosity, cP Initial, final plastic viscosity, cP Mud density, lb/gal. Density of cuttings, lb/gal. Initial, final mud density, lb/gal.

200

Reference Tables Nomenclature (continued) P = Pressure loss, psi Pa = Annulus pressure loss, psi Pc, Pca = Drill collar bore, annulus pressure loss, psi Pp, Ppa = Drill pipe bore, pipe annulus pressure loss, psi Ps = Surface connection pressure loss, psi Pt = Total system losses, psi Pb = Bit pressure loss, psi Q = Pump volume, GPM Qo = Optimum flow rate, GPM R = Bit rotational speed, RPM R1 = Rig cost or operating rate, dollars/hr. Re = Reynolds number, dimensionless ROP = Rate of penetration, ft/hr. ROP1, ROP2 = Initial, final rate of penetration, ft/hr. SS = Shear stress, dynes/cm2 Sr = Shear rate, sec.1 t = Round trip time, hr. = Rotating time for control, proposed bit, hr. T1, T2 , e = Apparent, effective viscosity, cP V = Fluid velocity, fps Vc = Critical velocity in annulus, fps Vn = Nozzle velocity, fps VS = Chip velocity, fpm W = Weight per inch of bit diameter, lb/in. Wb = Bit weight, 1,000 lb/in. of bit diameter WL1, WL2 = Initial, final water loss, cm3/30 min. YP = Yield point, lb/100 ft.2

Reference Tables Recommended Minimum Make-up Torque (ft/lb.) [See Note 2 page 203] Bore of Drill Collars Size and Type OD of Connection 1 11 4 11 2
API NC 23 27 8 PAC (See Note 4) 23 8 API IF API NC 26 27 8 SH 3 31 8 31 4 3 31 8 31 4 31 2 33 4 2,500 3,300 4,000 2,500 3,300 3,400 3,800 4,900 5,200 4,600 5,500 4,100 5,300 8,000 4,600 7,300 8,800 10,000 2,500 2,600 2,600 3,800 4,200 4,200 4,600 4,700 4,100 5,300 8,000 4,600 7,300 8,800 9,300 2,900 2,900 2,900 3,700 3,700 4,100 5,300 7,400 4,600 7,300 8,100 8,100 8,900 12,100 12,100 5,100 8,400 11,900 13,200 13,200 9,900 13,800 16,000 16,000 8,700 12,700 16,900 18,500 10,800 15,100 19,700 20,400 20,400

201

13 4

27 8 XH 33 4 31 2 DSL 37 8 27 8 MoD. oPeN 41 8 27 8 API IF API NC 31 31 2 SH API NC 35 37 8 41 8 41 4 41 2 41 2 43 4 5

41 4 31 2 XH 41 2 4 SH 43 4 31 2 Mod. Open 5 51 4 31 2 API IF API NC 38 41 2 SH 31 2 H-90 (See Note 3) 4 FH API NC 40 4 Mod. Open 41 2 DSL 43 4 5 51 4 51 2 43 4 5 51 4 51 2 5 51 4 51 2 53 4 6 51 4 51 2 53 4 6 61 4

4 H-90 (See Note 3)

Notes: 1. All dimensions are given in inches unless otherwise stated.

202

Reference Tables Recommended Minimum Make-up Torque (continued) (ft/lb.) [See Note 2] Bore of Drill Collars
2 21 4 21 2 213 16 3 31 4 31 2 313 16

4,600 6,800 6,800 6,800 8,900 10,800 10,800 5,100 8,400 11,700 11,700 11,700 9,900 13,800 14,600 14,600 8,700 12,700 16,700 16,700 10,800 15,100 18,600 18,600 18,600 12,500 17,300 22,300 23,500 23,500 8,900 9,200 9,200 5,100 8,400 10,000 10,000 10,000 9,900 12,800 12,800 12,800 8,700 12,700 15,000 15,000 10,800 15,100 16,900 16,900 16,900 12,500 17,300 21,500 21,500 21,500 7,400 7,400 7,400 5,100 8,200 8,200 8,200 8,200 9,900 10,900 10,900 10,900 8,700 12,700 13,100 13,100 10,800 14,800 14,800 14,800 14,800 12,500 17,300 19,400 19,400 19,400 8,300 8,300 8,300 8,300 8,700 10,400 10,400 10,400 10,800 12,100 12,100 12,100 12,100 12,500 16,500 16,500 16,500 16,500

Reference Tables Recommended Minimum Make-up Torque (ft/lb.) [See Note 2] Size and Type of Connection
41 2 API Reg

203

OD
1 5 2 53 4 6 61 4
1

Bore of Drill Collars

11 4 11 2 13 4

API NC 44

53 4 6 61 4 61 2 51 2 53 4 6 61 4 61 2 53 4 6 61 4 61 2 63 4 53 4 6 61 4 61 2 63 4 61 4 61 2 63 4 7 63 4 7 71 4 71 2 63 4 7 71 4 71 2 61 4 61 2 63 4 7 71 4

41 2 API FH

41 2 XH API NC 46 4 API IF 5 DSL 41 2 Mod. Open 4 2 H-90 (See Note 3)

1

5 H-90 (See Note 3)

51 2 H-90 (See Note 3)

5 2 API Reg.
1

41 2 API IF API NC 50 5 XH 5 Mod. Open 51 2 DSL

2. Basis of calculations for recommended make-up torque assumed the use of a thread compound containing 40 to 60 percent by weight of finely powdered metallic zinc or 60 percent by weight of finely powdered metallic lead, applied thoroughly to all threads and shoulders.

204

Reference Tables Recommended Minimum Make-up Torque (continued) (ft/lb.) [See Note 2] Bore of Drill Collars
2 15,400 20,300 23,400 23,400 20,600 25,000 25,000 25,000 12,900 17,900 23,300 27,000 27,000 21 4 15,400 20,300 21,600 21,600 20,600 23,300 23,300 23,300 12,900 17,900 23,300 25,000 25,000 17,600 23,200 28,000 28,000 28,000 17,600 23,400 28,500 28,500 28,500 25,000 31,500 35,000 35,000 34,000 41,500 42,500 42,500 31,500 39,000 42,000 42,000 22,800 29,500 36,000 38,000 38,000 21 2 15,400 19,400 19,400 19,400 20,600 21,200 21,200 21,200 12,900 17,900 22,800 22,800 22,800 17,600 23,200 25,500 25,500 25,500 17,600 23,400 26,000 26,000 26,000 25,000 31,500 33,000 33,000 34,000 40,000 40,000 40,000 31,500 39,000 39,500 39,500 22,800 29,500 35,500 35,500 35,500 213 16 15,400 16,200 16,200 16,200 18,000 18,000 18,000 18,000 12,900 17,900 19,800 19,800 19,800 17,600 22,200 22,200 22,200 22,200 17,600 23,000 23,000 23,000 23,000 25,000 29,500 29,500 29,500 34,000 36,500 36,500 36,500 31,500 36,000 36,000 36,000 22,800 29,500 32,000 32,000 32,000 12,900 17,700 17,700 17,700 17,700 17,600 22,200 22,200 22,200 22,200 17,600 21,000 21,000 21,000 21,000 25,000 27,000 27,000 27,000 34,000 34,000 34,000 34,000 31,500 33,500 33,500 33,500 22,800 29,500 30,000 30,000 30,000 22,800 26,500 26,500 26,500 26,500 3 31 4 31 2 33 4

Also using the modified jack screw formula as shown in the IADC Tool Pushers Manual and the API Spec. RP 7G (seventh edition, April 1976) and a unit stress of 62,500 psi in the box or pin, whichever is weaker.

Reference Tables Recommended Minimum Make-up Torque (continued) (ft/lb.) [See Note 2] Size and Type of Connection
51 2 API FH

205

OD
1 7 71 4 71 2 73 4 71 4 71 2 73 4 81 71 2 73 4 8 81 4 71 2 73 4 8 81 4 8 81 4 81 2 83 4 9 8 81 4 81 2 83 4 9 91 4 81 2 83 4 9 91 4 91 2 9 91 4 91 2 93 4 10 101 4 10 101 4 101 2 103 4 11

Bore of Drill Collars

11 4 11 2 13 4

API NC 56

65 8 API Reg.

65 8 H-90 (See Note 3)

API NC 61

51 2 API IF

65 8 API FH

API NC 70

API NC 77

206

Reference Tables Recommended Minimum Make-up Torque (continued) (ft/lb.) [See Note 2] Bore of Drill Collars
2 21 4 21 2 213 16 3 32,500 40,500 45,000 45,000 40,000 45,000 45,000 45,000 46,000 50,000 50,000 50,000 46,000 53,000 53,000 53,000 54,000 64,000 65,000 65,000 65,000 56,000 66,000 67,000 67,000 67,000 67,000 67,000 78,000 80,000 80,000 80,000 75,000 88,000 101,000 105,000 105,000 105,000 107,000 122,000 138,000 143,000 143,000 31 4 32,500 40,500 41,500 41,500 40,000 42,000 42,000 42,000 46,000 47,000 47,000 47,000 46,000 49,500 49,500 49,500 54,000 61,000 61,000 61,000 61,000 56,000 63,000 63,000 63,000 63,000 63,000 56,000 59,000 59,000 59,000 59,000 59,000 66,500 66,500 66,500 66,500 66,500 75,000 88,000 90,000 90,000 90,000 90,000 107,000 122,000 128,000 128,000 128,000 31 2 33 4 32,500 32,500 40,500 40,500 49,000 47,000 51,000 47,000 40,000 40,000 48,500 48,000 51,000 48,000 51,000 48,000 46,000 46,000 55,000 53,000 57,000 53,000 57,000 53,000 46,000 55,000 59,500 59,500 54,000 64,000 72,000 72,000 72,000 46,000 55,000 56,000 56,000 54,000 64,000 68,000 68,000 68,000

56,000 56,000 66,000 66,000 74,000 70,000 74,000 70,000 74,000 70,000 74,000 70,000 67,000 78,000 83,000 83,000 83,000 75,000 88,000 101,000 107,000 107,000 107,000

67,000 67,000 76,000 72,000 7,6000 72,000 76,000 72,000 76,000 72,000 75,000 75,000 88,000 88,000 100,000 95,000 100,000 95,000 100,000 95,000 100,000 95,000 107,000 107,000 122,000 122,000 138,000 133,000 138,000 133,000 138,000 133,000

Reference Tables Recommended Minimum Make-up Torque (continued) (ft/lb.) [See Note 2] Size and Type of OD Bore of Drill Collars 1 11 4 11 2 13 4 2 Connection
7 H-90 (See Note 3) 75 8 API Reg. Connections with Full Face 8 8*5 81 4* 1 8 2* 81 2* 8 83 4* 9* 91 4* 91 2* 9*5 91 4* 91 2* 8 10*5 101 4* 101 2*8 101 4* 101 2* Connections with Low Torque Face 8 83 4 95 91 4 91 2 93 4 105 93 4 8 105 101 4 101 2 103 4 8 115 5 103 4 11 111 4

207

21 4

75 8 H-90 (See Note 3) 85 8 API Reg. 85 8 H-90 (See Note 3) 7 H-90 (See Note 3) 75 8 API Reg.

75 8 H-90 (See Note 3) 85 8 API Reg. 85 8 H-90 (See Note 3)

3. Normal torque range tabulated minimum value to ten percent greater. Largest diameter shown for each connection is the maximum recommended for that connection. If the connections are used on drill collars larger than the maximum shown, increase the torque values shown by ten percent for a minimum value. In addition to the increased minimum torque value, it is also recommended that a fishing neck be machined to the maximum diameter shown. 4. H-90 connection make-up torque based on 56,250 psi stress and other factors as stated in note 1. 5. 27/8 in. PAC make-up torque based on 87,500 psi stress and other factors as stated in note 1.

208

Reference Tables Recommended Minimum Make-up Torque (continued) (ft/lb.) [See Note 2] Bore of Drill Collars
21 2 8 3 31 4 31 2 Connections with Full Face 53,000 53,000 53,000 53,000 63,000 63,000 63,000 60,500 71,500 68,500 68,500 68,500 60,000 60,000 860,000 71,000 71,000 71,000 79,000 83,000 83,000 79,000 88,000 83,000 79,000 88,000 83,000 72,000 72,000 72,000 85,500 85,500 85,500 98,000 98,000 98,000 108,000 108,000 108,000 123,000 123,000 123,000 139,000 134,000 129,000 112,500 112,500 112,500 128,500 128,500 128,500 Connections with Low Torque Face 67,500 66,500 62,000 867,500 74,000 71,000 66,500 62,000 72,000 72,000 72,000 85,000 85,000 82,000 91,000 87,000 82,000 91,000 87,000 82,000 91,000 91,000 91,000 8 105,000 105,000 103,500 112,500 108,000 103,500 112,500 108,000 103,500 112,000 112,000 112,000 8 129,000 129,000 129,000 5 92,500 92,500 92,500 110,000 110,000 110,000 128,000 128,000 128,000 213 16 33 4

60,000 71,000 74,000 74,000 74,000 72,000 85,500 95,500 108,000 123,000 123,000 112,500 128,500

72,000 877,000 77,000 77,000 91,000 98,000 98,000 98,000 112,000 129,000 92,500 110,000 128,000

*6. Largest diameter shown is the maximum recommended for those full face connections. If larger diameters are used, machine connections with low torque faces and use the torque values shown under low torque face tables. If low torque faces are not used, see note 2 for increased torque values. 7. Torque figures succeeded by a cross () indicate that the weaker member for the corresponding outside diameter and bore is the BOX. For all other torque values the weaker member is the PIN.

Reference Tables Rotary Shouldered Connection Interchange List Common Name Style Pin Base Size Dia. (tapered)
23 8 27 8 Internal Flush (IF) 31 2 4 41 2 Full Hole (FH) 4 27 8 Extra Hole (XH) (EH) 31 2 41 2 5 27 8 Slim Hole (SH) 31 2 4 41 2 31 2 Double Streamline (DSL) 41 2 51 2 2.876 3.391 4.016 4.834 5.250 4.280 3.327 3.812 4.834 5.250 2.876 3.391 3.812 4.016 3.327 4.280 5.250

209

Threads Taper Thread Form* Same As or per in. (in/ft.) Interchanges With
4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 V-0.065 (V-0.038 rad) V-0.065 (V-0.038 rad) V-0.065 (V-0.038 rad) V-0.065 (V-0.038 rad) V-0.065 (V-0.038 rad) V-0.065 (V-0.038 rad) V-0.065 (V-0.038 rad) V-0.065 (V-0.038 rad) V-0.065 (V-0.038 rad) V-0.065 (V-0.038 rad) V-0.065 (V-0.038 rad) V-0.065 (V-0.038 rad) V-0.065 (V-0.038 rad) V-0.065 (V-0.038 rad) V-0.065 (V-0.038 rad) V-0.065 (V-0.038 rad) V-0.065 (V-0.038 rad) 27 8 SH NC 26** 31 2 SH NC 31** 41 2 SH NC 38** 41 2 XH NC 46** 5 XH NC 50** 51 2 DSL 41 2 DSL NC 40** 31 2 DSL 4 SH 41 2 EF 4 IF NC 46** 41 2 IF NC 50** 51 2 DSL 23 8 IF NC 26** 27 8 IF NC 31** 31 2 XH 41 2 EF 31 2 IF NC 38** 27 8 XH 4 FH NC 40** 41 2 IF 5 XH NC 50**

210 Rotary Shouldered Connection Interchange List (continued) Common Name Style Pin Base Size Dia. (tapered)
26 31 38 Numbered Conn. (NC) 40 46 50 2.876 3.391 4.016 4.280 4.834 5.250

Reference Tables

Threads per in.

4 4 4 4 4 4

Taper Thread Form* Same As or (in/ft.) Interchanges With

2 2 2 2 2 2 V-0.038 rad 27 8 SH V-0.038 rad 31 2 SH V-0.038 rad V-0.038 rad V-0.038 rad 41 2 XH V-0.038 rad 23 8 IF 27 8 IF 31 2 IF 41 2 SH 4 FH 41 2 DSL 4 IF 41 2 IF 5 XH 51 2 DSL 4 SH 31 2 XH

41 2 External Flush (EF)

3.812

V-0.065 (V-0.038 rad)

** Connections with two thread forms shown may be machined with either thread form without affecting gauging or interchangeability. ** NC may be machined only with the V-0.038 radius thread form. Note: All dimensions are given in inches unless otherwise stated.

Reference Tables Top Sub Make-up Torque Table (ft/lb.) Series

3600 4500 5700 5800 6000 6100 7200 8200

211

Tool Connection
2 8 IF
3

Tool Top Sub OD

3 8
5

ID
1.00 1.25 2.25 1.50 2.25 1.50 2.25 2.25 3.00 2.25 3.00 2.81 2.81 3.00 2.25 3.00 3.00 3.00 3.00 3.50

Make-up Torque (ft/lb.)

5,700 6,350 6,350 17,800 17,800 23,500 23,500 28,000 28,000 60,600 51,500 54,000 54,000 51,500 60,600 88,000 88,000 88,000 88,000 88,000

31 2 IF 4 IF 4 IF 51 2 IF 65 8 Reg.

41 2 53 4 61 2 71 4 81 2

9500 11700 15000 22000

65 8 Reg. Servco T-20 Servco T-20 75 8 Reg. Servco T-20

81 2 111 2 111 2 133 8

Note: All dimensions are given in inches unless otherwise stated.

212 Recommended Maximum-Minimum Tool Joint Dimensions (in.)

A C B

Reference Tables

Joints
API Reg. API IF Hydril IF API Reg. API FH API IF Hydril IF Hughes XH Union Tool API Reg. API FH API IF Hydril IF Hughes XH API FH API IF Union Tool API Reg. API FH API IF Hydril IF Hughes XH API Reg. or UT API FH API IF API Reg. or UT API FH API IF API Reg. API Reg.

Nom. OD
31 8 33 8 33 8 33 4 41 4 41 8 37 8 41 4 41 4 41 4 45 8 43 4 41 2 43 4 51 4 53 4 53 4 53 4 53 4 61 8 67 8 67 8 63 4 77 8 73 8 73 4 87 8 81 2 87 8 107 8

Nom. ID
1 13 4 13 4 11 4 21 8 21 8 21 8 17 8 11 2 11 2 27 16 211 16 23 4 27 16 213 16 31 4 21 4 21 4 3 33 4 33 4 31 4 23 4 4 413 16 31 2 5 529 32 4 43 4

A Max.
11 8 13 4 13 4 13 8 21 8 21 8 23 16 17 8 11 2 13 4 27 16 211 16 23 4 27 16 213 16 35 16 27 8 25 8 35 32 33 4 37 8 31 4 31 4 4 413 16 4 5 529 32 41 4 51 4

B Max.
15 8 2 17 8 17 8 23 8 21 2 23 16 21 8 21 8 21 4 23 4 3 213 16 23 4 31 4 31 2 31 2 31 4 31 2 41 8 4 33 8 37 8 41 2 51 4 43 4 51 2 61 4 51 4 61 4

C Min. Max.
215 16 33 16 31 8 31 2 41 16 37 8 35 8 4 33 4 4 41 2 41 2 43 8 41 2 5 51 2 53 8 53 8 51 2 57 8 513 16 55 8 63 8 61 2 71 8 71 8 71 2 83 8 81 8 9 31 4 35 8 35 8 47 8 45 8 43 8 41 8 45 8 41 2 45 8 57 8 57 8 47 8 57 8 53 8 67 8 67 8 67 8 67 8 61 2 61 4 61 4 77 8 71 4 77 8 77 8 81 4 97 8 97 8 101 8

2 8
3

27 8

31 2

41 2

51 2

65 8 75 8 85 8

Reference Tables

213

Drill PiPe Data

Internal Upset Size 23 8
27 8

Pipe OD
2.375 2.375 2.875 2.875 2.875 3.500 3.500 3.500 3.500 4.000 4.000 4.500 4.500

Wt. (lb.)
4.80 6.65 6.45 8.35 8.50

ID Pipe
2.000 1.815 2.469 2.323 3.063

ID Upset
1.437 1.125 1.875 1.625 1.187 2.437 2.125 1.875 1.750 2.375 2.250 3.250 3.156 2.812 2.687 2.812

Size
5 51 2

Pipe OD

Wt. (lb.)

ID Pipe
4.276 4.778 4.670 4.975 4.859 4.733 6.065 5.965 5.761 6.969 7.825

ID Upset
3.781 3.812 3.500 4.125 3.812 3.500 5.187 5.000 4.625 6.000 6.625

5.000 19.50 5.500 21.90 5.500 24.70 5.563 19.00 5.563 22.20 5.563 25.25 6.625 22.20

10.40 2.151 11.20 2.900 13.30 2.764 15.50 2.602 14.00 3.340 15.70 3.240 12.75 4.000 13.75 3.958 16.60 3.826 18.10 3.754 20.00 3.640

59 16

31 2

6 8
5

6.625 25.20 6.625 31.90 7.625 29.25 8.625 40.00

7 8
5

85 8

4 2
1

4.500 4.500 4.500

External Upset Size

23 8 27 8 31 2 4

Pipe OD
2.375 2.875 3.500 3.500 4.000 4.000

Wt. (lb.)
6.65 10.40 13.30 15.50 14.00 15.70

ID Pipe
1.815 2.151 2.764 2.602 3.340 3.240

ID Upset
2.656 3.219 3.824 3.824 4.500 4.500

Size
41 2 59 16 6 8
5

Pipe OD
4.500 4.500 5.563 5.563 6.625

Wt. (lb.)
16.60 20.00 22.20 25.25 25.20

ID Pipe
3.826 3.640 4.859 4.733 5.965

ID Upset
5.000 5.000 6.063 6.063 7.125

Note: All dimensions are given in inches unless otherwise stated.

214

Reference Tables

Hevi-wate Drill PiPe

Capacity and Displacement Table Hevi-Wate Drill Pipe Nom. Size (in.)
31 2 4 41 2 5

Capacity gal. per Joint*

5.30 8.13 9.37 11.14

Displacement bbl per 100 ft.

.421 .645 .743 .883

bbl per Joint*

.126 .194 .223 .265

gal. per 100 ft.

17.7 27.1 31.2 37.1

gal. per Joint*

11.61 13.62 18.82 22.62

bbl per Joint*

.276 .325 .448 .539

gal. per 100 ft.

38.7 45.4 62.7 75.4

bbl per 100 ft.

.921 1.082 1.493 1.796

* Capacity and displacement per joint numbers are based on 30 ft. joints.

Reference Tables

215

Hevi-wate Drill PiPe

Dimensional Data Range II Nom. Size ID
31 2 4 41 2 5 21 16 29 16 23 4 3

Tube Normal Tube Dim. Wall Thickness

.719 .719 .875 1.000

Area (in.2)
6.280 7.409 9.965 12.566

Center Upset
4 41 2 5 51 2

Elevator Upset Tensile Yield Torsional (lb.) Yield (ft/lb.)

35 8 41 8 45 8 51 8 345,400 407,550 548,075 691,185 19,575 27,635 40,715 56,495

Mechanical Properties Tube Section

Dimensional Data Range II Nom. Size Tool Joint Connection Size OD ID Approx. Wt. Makeup Mechanical Properties Incl. Tube and Joints Torque (lb.) (ft/lb.) Tensile Torsional wt/ft. 30 ft. Yield (lb.) Yield wt/jt. (ft/lb.)
31 2 4 41 2 5 NC 38(31 2 IF) NC 40(4 FH) NC 46(4 IF) NC 50(41 2 IF) 43 4 5 4
1

23 16 2 16
11

748,750 711,475 1,024,500 1,266,000

17,575 23,525 38,800 51,375

25.3 29.7

760 880

9,900 13,250 21,800 29,400

61 4 61 2

27 8 31 16

41.0 1,230 49.3 1,480

Note: All dimensions are given in inches unless otherwise stated.

216

Reference Tables

tubing Data
Non-upset API Size
1.900

OD
1.900 2.375 2.375 2.875 3.500 3.500 3.500 4.000 4.500

lb.
2.75 4.00 4.60 6.40 7.70 9.20 10.20 9.50 12.60

ID
1.610 2.041 1.995 2.441 3.068 2.992 2.922 3.548 3.958

Coupling OD
2.200 2.875 2.875 3.500 4.250 4.250 4.250 4.750 5.200

23 8
23 8 27 8 3 2
1

3 2
1

3 2
1

4 41 2

External Upset API Size

1.660 1.900

OD
1.660 1.900 2.375 2.875 3.500 4.000 4.500

lb.
2.40 2.90 4.70 6.50 9.30 11.00 12.75

ID
1.380 1.610 1.995 2.441 2.992 3.476 3.958

Coupling OD
2.200 2.500 3.063 3.668 4.500 5.000 5.563

23 8
2 8
7

31 2 4 41 2

Note: All dimensions are given in inches unless otherwise stated.

Reference Tables

217

Drill Collar weigHts (lb/ft.)

Collar OD
3 8 31 2 33 4 37 8 43 8 41 8 41 4 41 2 43 4 53 8 51 4 51 2 53 4 63 8 61 4 61 2 63 4 73 8 71 4 71 2 73 4 83 8 81 4 81 2 83 4 93 8 91 2 103 8 101 2 113 8
3

Bore of Collar (in.)

11 2 24.4 26.7 31.5 34.0 36.7 39.4 42.2 48.0 54.2 60.1 67.5 74.7 82.1 89.9 98.1 106.6 115.5 124.6 134.1 143.9 154.1 164.6 175.4 186.6 198.1 13 4 22.2 24.5 29.3 31.9 34.5 37.2 40.0 45.8 52 58.5 65.3 72.5 79.9 87.8 95.9 104.5 113.3 122.5 131.9 141.7 151.9 162.5 173.3 184.4 195.9 207.8 232.4 2 21 4 21 2 23 4 3 31 4 31 2 33 4 4

29.4 32.0 34.7 37.5 43.3 49.5 55.9 62.8 69.9 77.5 85.3 93.5 101.9 110.8 119.9 129.5 139.3 149.5 159.9 170.8 181.9 193.9 205.3 229.9 255.9 283.3

26.5 29.2 31.9 34.7 40.5 46.7 53.1 59.9 67.2 74.6 82.5 90.6 99.1 107.9 117.1 126.6 136.5 146.6 157.1 167.9 179.1 190.6 202.4 227.1 253.1 280.4

43.5 49.9 56.8 63.9 71.5 79.3 87.5 95.9 104.8 113.9 123.5 133.3 143.5 153.9 164.8 175.9 187.4 199.3 223.9 249.9 277.3 305.9

53.3 60.5 67.9 75.8 83.9 92.5 101.3 110.5 119.9 129.8 139.9 150.5 161.3 168.6 183.9 195.8 220.4 246.4 273.8 302.4

56.7 64.1 71.9 80.1 88.6 97.5 106.6 116.1 125.9 136.1 146.6 157.5 172.5 180.1 191.9 216.6 242.6 269.9 298.6

67.8 75.9 84.5 93.3 102.5 111.9 121.8 131.9 142.5 153.3 164.5 175.9 187.8 212.4 238.4 265.8 294.4

63.3 71.5 79.9 88.8 97.9 107.5 117.3 127.5 137.9 148.8 159.9 171.4 183.3 207.9 233.9 261.3 289.9

93.1 102.6 112.5 122.6 133.1 143.9 155.1 166.6 178.5 203.1 229.1 256.4 285.1

87.9 97.5 107.3 117.5 127.9 138.8 149.9 161.5 173.3 197.9 223.9 251.3 279.9

To obtain the weights of spiral collars, subtract four percent.

218

Reference Tables

weigHts of 30 ft. Drill Collars (lb.)

Collar OD
3 8 31 2 33 4 37 8 41 2 41 8 41 4 41 2 43 4 51 2 51 4 51 2 53 4 61 2 61 4 61 2 63 4 71 2 71 4 71 2 73 4 81 2 81 4 81 2 83 4 91 2 91 2 101 2 101 2 111 2
3

Bore of Collar (in.)

11 2 730 799 944 1,020 1,099 1,180 1,264 1,439 1,624 1,819 2,024 2,239 2,464 2,699 2,944 3,199 3,463 3,738 4,023 4,318 4,623 4,938 5,263 5,598 5,943 13 4 665 734 879 955 1,034 1,115 1,199 1,374 1,559 1,754 1,959 2,174 2,399 2,634 2,879 3,134 3,398 3,673 3,958 4,253 4,558 4,873 5,198 5,533 5,878 6,233 6,972 2 21 4 21 2 23 4 3 31 4 31 2 33 4 4

880 959 1,040 1,124 1,299 1,484 1,679 1,884 2,099 2,324 2,559 2,804 3,059 3,323 3,598 3,883 4,178 4,483 4,798 5,123 5,458 5,803 6,158 6,897 7,677 8,497

795 874 955 1,039 1,214 1,399 1,594 1,799 2,014 2,239 2,474 2,719 2,974 3,238 3,513 3,798 4,093 4,398 4,713 5,038 5,373 5,718 6,073 6,812 7,592 8,412

1,304 1,499 1,704 1,919 2,144 2,379 2,624 2,879 3,143 3,418 3,703 3,998 4,303 4,618 4,943 5,278 5,623 5,978 6,498 7,497 8,317 9,177

1,599 1,814 2,039 2,274 2,519 2,774 3,039 3,313 3,598 3,893 4,198 4,513 4,838 5,058 5,518 5,873 6,717 7,392 8,212 9,072

1,699 1,924 2,159 2,404 2,659 2,924 3,199 3,483 3,778 4,083 4,398 4,723 5,173 5,403 5,758 6,613 7,277 8,097 8,957

2,034 2,279 2,534 2,799 3,074 3,358 3,653 3,958 4,273 4,598 4,933 5,278 5,633 6,373 7,152 7,972 8,832

1,899 2,144 2,399 2,664 2,939 3,223 3,518 3,823 4,138 4,463 4,798 5,143 5,498 6,238 7,017 7,837 8,697

2,794 3,078 3,373 3,678 3,993 4,318 4,653 4,998 5,353 6,093 6,872 7,692 8,552

2,639 2,924 3,219 3,523 3,838 4,163 4,498 4,843 5,198 5,938 6,717 7,537 8,397

To obtain the weights of spiral collars, subtract four percent.

Reference Tables

219

buoyanCy faCtor anD safety faCtor

Buoyancy Effect on the Drillstring Due to the buoyancy effect, all drill collar weight is not actually available for loading the bit in fluid-drilled holes. To find the corrected, or buoyed, drill collar weight, use the buoyancy correction factor from the Buoyancy Factors table on page 220 of this section. Example: A drill collar string weighs 79,000 lb. in air. How much will it weigh in 12 lb/gal. mud? Buoyed drill collar weight = Drill collar weight x buoyancy factor = 79,000 lb. x .817 = 64,543 lb. Safety Factor Drill pipe can be seriously damaged if run in compression. To make sure the drill pipe is always in tension, the top ten to 15 percent of the drillstring has to be in tension. This will shift the point of changeover from tension to compression, i.e., the neutral zone, down to the stiff drill collar string, where it can be tolerated. The calculation of the maximum bit weight available therefore has to include a ten to 15 percent Safety Factor (SF), written as 1.10 or 1.15. In harder formations, the SF should increase up to 25 percent. Example: Using the same example as above: Maximum bit weight available = Buoyed drill collar weight = 1.15 64,543 lb. = 1.15 56,124 lb. The buoyed weight of the drill collar string, incorporating the SF, is thus 56,124 lb.

220

Reference Tables

buoyanCy faCtors
Mud Weight lb/gal.
8.4 8.6 8.8 9.0 9.2 9.4 9.6 9.8 10.0 10.2 10.4 10.6 10.8 11.0 11.2 11.4 11.6 11.8 12.0 12.2 12.4 12.6 12.8

Buoyancy Factor
.872 .869 .866 .863 .860 .856 .853 .850 .847 .844 .841 .838 .835 .832 .829 .826 .823 .820 .817 .814 .811 .808 .805

Mud Weight lb/gal.

13.0 13.2 13.4 13.4 13.6 14.0 14.2 14.4 14.6 14.8 15.0 15.2 15.4 15.6 15.8 16.0 16.2 16.4 16.6 16.8 17.0 17.2 17.4

Buoyancy Factor
.801 .798 .795 .795 .792 .786 .783 .780 .777 .774 .771 .768 .765 .76 .759 .755 .753 .750 .747 .744 .740 .737 .734

Mud Weight lb/gal.

17.6 17.8 18.0 18.2 18.4 18.6 18.8 19.0 19.2 19.4 19.6 19.8 20.0 20.2 20.4 20.6 20.8 21.0 22.0 23.0 24.0

Buoyancy Factor
.731 .728 .725 .723 .720 .717 .714 .711 .708 .705 .702 .698 .694 .691 .688 .685 .682 .679 .664 .649 .633

Reference Tables 10 in. Duplex Pump Strokes per Min.

25 30 35 40 45 50 55 60 65 70 75 80 85

221

Gallons per Minute Using Liner Shown

3 31 2 30 30 40 40 40 50 50 60 60 40 40 50 50 60 70 4 50 60 70 70 41 2 60 70 5 80 51 4 51 2 53 4 90 6 61 4 61 2 63 4 7 71 4 71 2 8

90 100 110 120 130 140 150 170 180 200

90 100 110 120 140 150 160 170 190 200 210 240

90 110 120 130 140 160 170 190 200 220 230 250 280 90 120 130 140 160 170 190 200 220 230 250 270 310

80 110 130 150 160 180 190 210 230 240 260 280 300 350 90 120 150 160 180 200 210 230 250 270 290 310 340 380

70 100 130 160 180 200 220 230 260 280 300 320 350 370 420 80 110 140 180 190 210 230 260 280 300 330 350 380 400 460 90 120 150 190 210 230 250 280 300 330 350 380 410 440 500

70 100 130 160 200 230 250 270 300 330 350 380 410 440 470 540 70 100 140 180 220 240 270 290 320 350 380 410 440 470 510 580 80 110 150 190 230 260 290 310 340 370 400 440 470 500 540 620 80 120 150 200 250 280 300 330 360 390 430 460 500 540 570 650

Pump Volume vs. Liner Size Liner sizes vary depending on the pump size, strokes per minute and required circulation rate in GPM. The following tables give the circulation rates possible when various sizes of duplex and triplex pumps are used, based on the pumps volumetric efficiency of 95 percent. GPM calculated in ten GPM increments for purposes of reading curves and proper orifice selection.

222 12 in. Duplex Pump Strokes per Min.

25 30 35 40 45 50 55 60 65 70

Reference Tables

Gallons per Minute Using Liner Shown

41 2 70 43 4 80 5 51 4 5 51 2 53 4 6 61 4 61 2 63 4 7 71 4 150 190 220 230 260 290 320 350 380 410

90 100 110 120 130 140 160 170 180 200

90 100 110 120 130 150 160 170 190 200 220 240 100 110 130 140 150 170 190 200 220 240 260 280 110 120 140 150 170 180 200 220 240 260 280 300 120 140 150 170 190 210 230 250 270 290 310 340 140 150 170 190 210 230 250 270 300 320 350 370 150 170 190 210 230 250 280 300 330 350 380 410 160 180 200 230 250 280 300 330 360 390 420 450 180 200 220 250 270 300 330 360 390 420 450 490 190 210 240 270 290 320 350 380 420 450 490 520

14 in. Duplex Pump Strokes per Min.

25 30 35 40 45 50 55 60 65 70

Gallons per Minute Using Liner Shown

43 4 5 51 4 51 2 53 4 6 61 4 61 2 63 4 7 71 4 71 2 73 4

90 100 110 130 140 150 170 180 190 210 230 240 260 110 120 140 150 170 180 200 220 230 250 270 290 310 130 140 160 180 190 210 230 250 270 290 320 340 360 140 150 170 190 210 230 250 270 290 320 340 370 390 150 170 190 210 240 260 280 310 330 360 390 410 440 170 190 210 240 260 290 310 340 370 400 430 460 490 190 210 240 260 290 320 340 370 410 440 470 510 540 210 230 260 290 310 340 380 410 440 480 510 550 590 220 250 280 310 340 370 410 440 480 520 560 600 640 240 270 300 330 370 400 440 480 520 560 600 640 690

Reference Tables 15 in. Duplex Pump Strokes per Min.

25 30 35 40 45 50 55 60 65 70

223

Gallons per Minute Using Liner Shown

5 110 130 150 170 190 210 230 250 270 290 5 4
1

5 2
1

53 4 150 180 210 220 250 280 310 340 360 390

6 160 190 230 250 280 310 340 370 400 430

61 4 180 210 250 270 300 340 370 400 440 470

61 2 190 230 270 290 330 360 400 440 470 510

63 4 210 250 290 320 360 400 430 470 510 550

7 230 270 320 340 380 430 470 510 550 600

71 4 240 290 340 370 410 460 510 550 600 640

71 2 260 310 360 390 440 490 540 590 640 690

73 4 280 330 390 420 480 530 580 630 690 740

120 150 170 180 210 230 250 280 300 320

130 160 190 200 230 250 280 310 330 360

16 in. Duplex Pump Stroke per Min.

25 30 35 40 45 50 55 60 65 70

Gallons per Minute Using Liner Shown

4 4
3

5 4 5 2 53 4
1 1

61 4 61 2 63 4

71 4 71 2 73 4

81 4 81 2

100 110 130 140 150 170 190 200 220 240 260 270 290 310 340 360 120 140 150 170 190 200 220 240 260 280 310 330 350 380 400 430 140 160 180 200 220 240 260 280 310 330 360 380 410 440 470 500 150 170 190 210 230 260 280 310 330 360 390 420 450 480 510 540 170 190 220 240 260 290 320 340 370 400 440 470 500 540 570 610 190 210 240 270 290 320 350 380 420 450 480 520 560 600 640 680 210 240 260 290 320 350 390 420 460 490 530 570 610 660 700 740 230 260 290 320 350 390 420 460 500 540 580 620 670 720 760 810 250 280 310 350 380 420 460 500 540 580 630 680 720 770 830 880 270 300 330 370 410 450 490 540 580 630 680 730 780 830 890 950

224 18 in. Duplex Pump Stroke per Min.

25 30 35 40 45 50 55 60 65 70

Reference Tables

Gallons per Minute Using Liner Shown

5 51 4 51 2 53 4 6 61 4 61 2 63 4 7 71 4 71 2 73 4 8 81 4 81 2 81 2

130 140 160 170 190 210 230 250 270 290 310 330 350 150 170 190 210 230 250 270 300 320 340 370 400 420 180 200 220 240 270 290 320 350 370 400 430 460 500 190 220 240 260 290 320 340 370 400 440 470 500 540 220 240 270 300 330 360 390 420 450 490 530 560 600 240 270 300 330 360 400 430 470 510 540 590 630 670 270 300 330 360 400 440 470 510 560 600 640 690 740 290 320 360 400 430 480 520 560 610 650 700 750 800 310 350 390 430 470 510 560 610 660 710 760 820 870

380 400 360 450 480 430 530 560 500 570 610 540 640 690 610 720 760 680 790 840 740 860 910 810 930 990 880

340 380 420 460 510 550 600 650 710 760 820 880 940 1,000 1,070 950

20 in. Duplex Pump Stroke per Min.

25 30 35 40 45 50 55 60 65 70

Gallons per Minute Using Liner Shown

5 51 4 51 2 53 4 6 61 4 61 2 63 4 7 71 4 71 2 73 4 8 390 470 550 600 670 750 820 890 81 4 420 500 590 640 720 790 870 81 2 81 2 450 360 540 430 630 500 680 540 760 610 850 680 930 740

140 160 180 190 210 220 250 270 300 320 340 370 170 190 210 230 250 260 300 330 360 380 410 440 200 220 250 270 300 310 350 380 410 450 480 510 210 240 270 290 320 350 380 420 450 480 520 560 240 270 300 330 360 400 430 470 510 540 590 630 270 300 330 370 400 440 480 520 560 610 650 700 290 330 370 400 440 480 530 570 620 670 720 770 320 360 400 440 480 530 570 620 670 730 780 840 350 390 430 480 520 570 620 680 730 790 850 910

950 1,020 810

970 1,030 1,100 880

370 420 460 510 560 620 670 730 790 850 910 980 1,040 1,110 1,180 950

Reference Tables 7 in. Stroke, Triplex Pump Strokes per Minute

40 60 70 80 90 100 110 120 140 160

225

Gallons per Minute Using Liner Shown

41 2 60 80 100 110 120 140 150 170 190 220 5 70 100 120 140 150 170 190 200 240 270 51 2 80 120 140 160 180 200 230 250 290 330 6 100 150 170 200 220 240 270 290 340 390 61 2 120 170 200 230 260 290 320 340 400 460 7 130 200 230 270 300 330 370 400 470 530

8 in. Stroke, Triplex Pump Strokes per Minute

40 60 70 80 90 100 110 120 140 160 180

Gallons per Minute Using Liner Shown

3 30 40 50 60 60 70 80 80 100 110 130 31 4 30 50 60 70 70 80 90 100 120 130 150 31 2 40 60 70 80 90 100 110 120 130 150 170 4 50 80 90 100 110 120 140 150 170 200 220 41 2 60 90 110 130 140 160 170 190 220 250 280 5 80 120 140 160 170 190 210 230 270 310 350 51 2 100 140 160 190 210 240 260 280 330 380 420 6 110 170 200 220 250 280 310 340 390 450 500 61 4 120 180 210 240 270 300 330 360 430 490 550

226 81/2 in. Stroke, Triplex Pump Strokes per Minute

40 60 70 80 90 100 110 120 140 160 180

Reference Tables

Gallons per Minute Using Liner Shown

41 4 60 90 100 120 130 150 160 180 210 240 270 41 2 70 100 120 130 150 170 180 200 230 270 300 43 4 70 110 130 150 170 190 200 220 260 300 330 5 80 120 140 160 190 210 230 250 290 330 370 51 4 90 140 160 180 200 230 250 270 320 360 410 51 2 100 150 170 200 220 250 270 300 350 400 450 53 4 110 160 190 220 250 270 300 330 380 440 490 6 120 180 210 240 270 300 330 360 420 470 530 61 4 130 190 230 260 290 320 350 390 450 520 580

9 in. Stroke, Triplex Pump Strokes per Minute

40 60 70 80 90 100 110 120 130 140 150

Gallons per Minute Using Liner Shown

41 4 70 110 120 140 160 180 190 210 230 250 270 41 2 90 130 150 170 200 220 240 260 280 310 330 43 4 110 160 180 210 240 260 290 320 340 370 390 5 130 190 220 250 280 310 350 380 410 440 470 51 4 140 200 240 270 310 340 370 410 440 480 510

Reference Tables 91/4 in. Stroke, Triplex Pump Strokes per Minute
40 60 70 80 90 100 110 120 130 150 170

227

Gallons per Minute Using Liner Shown

41 2 70 110 130 150 160 180 200 220 240 270 310 43 4 80 120 140 160 180 200 220 240 260 300 340 5 90 130 160 180 200 220 250 260 290 340 380 51 4 100 150 170 200 220 250 270 300 320 370 420 51 2 110 160 190 220 240 270 300 330 350 410 460 53 4 120 180 210 240 270 300 330 360 390 450 510 6 130 190 230 260 290 320 360 390 420 490 550 61 4 140 210 250 280 320 350 390 420 460 530 600

10 in. Stroke, Triplex Pump Strokes per Minute

40 40 60 70 80 90 100 110 120 130 140 160

Gallons per Minute Using Liner Shown

51 4 70 110 160 190 210 240 270 290 320 350 370 430 51 2 90 120 180 210 230 260 290 320 350 380 410 470 53 4 110 130 190 220 260 290 320 350 390 420 450 510 6 130 140 210 240 280 310 350 380 420 450 490 560 61 4 140 150 230 280 300 340 380 420 450 490 530 610

228 11 in. Stroke, Triplex Pump Strokes per Minute

40 50 60 70 80 90 100 110 120 130

Reference Tables

Gallons per Minute Using Liner Shown

51 2 130 160 190 230 260 290 320 350 390 420 6 150 190 230 270 310 350 380 420 460 500 61 2 180 230 270 320 360 410 450 500 540 590 7 210 260 310 370 420 470 520 580 630 680

12 in. Stroke, Triplex Pump Strokes per Minute

40 50 60 70 80 90 100 110 120 130 140

Gallons per Minute Using Liner Shown

51 2 140 180 210 250 280 320 350 390 420 460 490 53 4 150 190 230 270 310 350 390 420 460 500 540 6 170 210 250 290 330 380 420 460 500 540 590 61 4 180 230 270 320 360 410 450 500 550 590 640 61 2 200 250 300 340 390 440 490 540 590 640 690 63 4 210 270 320 370 420 480 530 580 640 690 740 7 230 290 340 400 460 510 570 630 680 740 800 71 4 240 310 370 430 490 550 610 670 730 800 860

Reference Tables Hardness Conversion Table - Approximate Values Rockwell C

66 65 64 62 60 59 58 57 55 54 52 51 50 49 47 46 45 43 42 40 39 38 37 36 34 33 32 745 712 682 653 627 601 578 555 534 514 495 477 461 444 429 415 401 388 375 363 352 341 331 321 311 302

229

Brinell No. C
31 30 29 28 27 25 24 23 22 21 19 18 16 15 14 13 12 10 9 8 6 5 4

Rockwell B

Brinell No.
293 285 277 269 262 255 248 100 99 98 97 96 96 95 94 93 92 91 90 89 88 87 86 241 235 229 223 217 212 207 201 197 192 187 183 179 174 170 167

230 Impression Diameter Hardness Table Brinell 500 kg Dia. 3,000 kg B.H.N.
2.00 2.05 2.10 2.15 2.20 2.25 2.30 2.35 2.40 2.45 2.50 2.55 2.60 2.65 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50 3.55 3.60 3.65 3.70 3.75 3.80 3.85 3.90 3.95 158 150 143 136 130 124 119 114 109 105 100 96 93 89 86 83 80 77 74 72 70 67 65 63 61 59 57 55 54 52 50 49 48 46 45 44 43 41 40 39 946 896 857 817 782 744 713 683 652 627 600 578 555 532 512 495 477 460 444 430 418 402 387 375 364 351 340 332 321 311 302 293 286 277 269 262 255 248 241 235

Reference Tables

Rockwell C B Tensile

Rockwell hardness and tensile strengths apply only to B.H.N. with 3,000 kg load 68 67 65 63 62 60 58 56 55 53 52 50 48 47 46 44 43 42 41 39 38 37 36 35 34 32 31 30 29 28 27 26 25 24 23 22 368 360 354 341 329 317 305 295 284 273 263 253 242 233 221 211 202 193 185 178 171 165 159 154 148 143 139 135 131 127 124 121 117 115 112 109

120 119 119 117 116 116 115 114 114 113 112 112 110 110 109 108 108 107 106 105 104 104 104 103 102 102 100 99

Reference Tables Impression Diameter Hardness Table (continued) Brinell Dia. 500 kg 3,000 kg C B.H.N.
4.00 4.05 4.10 4.15 4.20 4.25 4.30 4.35 4.40 4.45 4.50 4.55 4.60 4.65 4.70 4.75 4.80 4.85 4.90 4.95 5.00 5.05 5.10 5.15 5.20 5.25 5.30 5.35 5.40 5.45 5.50 5.55 5.60 5.65 5.70 5.75 5.80 5.85 5.90 5.95 38.0 37.0 36.0 35.0 34.5 33.6 32.6 32.0 31.2 30.4 29.7 29.1 28.4 27.8 27.2 26.5 25.9 25.4 24.9 24.4 23.8 23.3 22.8 22.3 21.8 21.5 21.0 20.6 20.1 19.7 19.3 19.0 18.6 18.2 17.8 17.5 17.2 16.9 16.6 16.2 228 223 217 212 207 202 196 192 187 183 179 174 170 166 163 159 156 153 149 146 143 140 137 134 131 128 126 124 121 118 116 114 112 109 107 105 103 101 99 97

231

Rockwell B
98 97 96 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 74 73 72 71 70 69 68 67 66 65 64 62 61 60 59 57

Tensile
107 105 103 100 98 96 95 93 91 89 87 85 84 82 81 79 78 76 75 74 72 71 70 68 66 65 64 63 62 61 60 59 58 56 55 54 53 52 51 50

21 20 18 17 16 15 14 12 12 11 10 9 8 7 6 5 4 3 2 1 0 -2 -3

232

Reference Tables

Conversion faCtors - fraCtion to DeCimal

1 1 3 1 5 3 7

64 32 64 16 64 32 64 8 64 32 64 64 64 16 32 4

.0156 .0312 .0468 .0625 .0781 .0937 .1093 .1250 .1406 .1562 .1718 .1875 .2031 .2187 .2343 .2500

17 9

64

.2656 .2812 .2968 .3125 .3281 .3437 .3593 .3750 .3906 .4062 .4218 .4375 .4531 .4687 .4843 .5000

33 17

64

.5156 .5312 .5468 .5625 .5781 .5937 .6093 .6250 .6406 .6562 .6718 .6875 .7031 .7187 .7343 .7500

49 25 51 13 53 27 55 7

64 32 64 16 64 32 64 64 32 64 16 64 32 64

.7656 .7812 .7968 .8125 .8281 .8437 .8593 .8750 .8906 .9062 .9218 .9375 .9531 .9687 .9843 1.0000

32 64 64 64 8 64 32 64 64 32 64 2 16 32

32 64 64 32 64 8 64 32 64 64 32 64 4

19 5

35 9

16

21 11

37 19 39

23

1 9 5

3 25 13 27 7

5 41 21 43 11

57 29 59 15 61 31 63

11 3

16

16

13 7

29 15 31

45 23 47

15

Reference Tables

233

Conversion faCtors - englisH anD metriC

Acres Acres Acres Barrels, water Barrels, water Barrels, oil (API) Barrels per day Centimeter Cubic centimeters Cubic feet Cubic feet Cubic feet Cubic feet Cubic feet Cubic feet Cubic feet per minute Cubic inches Cubic yards Cubic yards Degrees (angle) Degree Fahrenheit (F) Feet Feet Feet Feet Feet of water (depth) Feet Foot pounds Foot pounds Furlongs Gallons(imperial) Gallons (imperial) Gallons (U.S.) Gallons (U.S.) Gallons (U.S.) Gallons (U.S.) Gallons per minute Gallons per minute Grains Grams Inches Inches Inches of water

Multiply

43,560 0.001562 4,840 31.5 263 42.0 0.02917 0.3937 0.006102 1,728 0.03704 7.481 0.1781 28.3160 0.03704 0.4719 16.3871 27 0.764555 0.01745 [Degree F-32]1.8 (or x 5/9) 30.48 12 0.3048 .0001894 .4335 0.3048 1.35582 0.138255 660 1.209 4.54609 3,785.434 .02381 .1337 3.785 .002228 34,286 64.79891 .03527 .08333 25.4 .03613

By

Square feet Square miles Square yards Gallons Pounds Gallons Gallons per minute Inches Cubic inches Cubic inches Cubic yards Gallons Barrels (oilfield) Liters Cubic yards Liter per second Cubic centimeters Cubic feet Cubic meters Radians Degree Celsius (C) Centimeters Inches Meters Miles Pounds per square inch Meters Joules Meter-kilograms Feet Gallons (U.S.) Liters Cubic centimeters Barrels, oil Cubic feet Liters Cubic feet per second Barrels per day Milligrams Ounces Feet Millimeters Pounds per square inch

To Obtain

234

Reference Tables

Conversion faCtors (ContinueD) - englisH anD metriC

Kilometers Kilometers Kilometers per hour Knots Knots Knots per hour Liters Liters Meters Meters Meters Miles Miles Miles Miles per hour Miles per hour Miles per hour Minutes Minutes (angle) Minutes (angle) Ounces (fluid) Ounces per cubic inch Paschal (unit or force, pressure) Pints Pints Pounds Pounds Pounds of water Pounds of water Pounds of water Pounds per cubic foot Pounds per cubic foot Pounds per square foot Pounds per square foot Pounds per square inch Pounds per square inch Pounds per square inch Quarts (U.S.) Quarts (U.S.) Quarts (U.S.) Radians Radians per second

Multiply

3,281 .6214 .6214 6,080 1.152 1.152 .03531 .2642 3.281 39.37 1.094 5,280 1.609 1,760 88 1.609 .8684 .01667 .0002909 60 1.805 1.72999 1.0 28.87 .125 453.6 .4536 .01602 27.68 .1198 .01602 16.0185 4.88241 47.8803 2.307 2.036 0.689476 57.75 946.4 0.946331 57.30 9.549

By

Feet Miles Miles per hour Feet Miles Miles per hour Cubic feet Gallons Feet Inches Yards Feet Kilometers Yards Feet per minute Kilometers per hour Knots per hour Hours Radians Seconds (angle) Cubic inches Grams per cubic centimeter Newton per square meter cubic inches Gallons Grams Kilograms Cubic feet of water Cubic inches of water Gallons Grams per cubic centimeter Kilograms per cubic meter Kilograms per square meter Newtons per square meter Feet of water Inches of mercury Newtons per square cm Cubic inches Cubic centimeters Liters Degrees Revolutions per minute

To Obtain

Reference Tables

235

Conversion faCtors (ContinueD) - englisH anD metriC

Multiply
Square centimeters Square feet Square feet Square feet Square inches Square inches Square miles Square miles Square kilometer Square meters Square meters Square yards Square yards Temperature (C) Temperature (F) Tons (long) Tons (metric) Tons (short) Yards Yards

By
.1550 144 .00002296 929 6.4516 .006944 640 2.59 247.1 10.76 .0002471 9 .8361 or 0.5556 (subtract 32) 2,240 2,205 2,000 .9144 91.44
5/9

To Obtain
Square inches Square inches Acres Square centimeters Square centimeters Square feet Acres Square kilometers Acres Square feet Acres Square feet Square meters Temp. (F) Temp. (C) Pounds Pounds Pounds Meters Centimeters

1.8 (add 32)

236 Notes:

Reference Tables

Index of Product References

Anchor-Stock, Retrievable .................................................... 67 API Casing Data ................................................................. 232 Areas of Circle and Nozzles ............................................... 151 Bit Selection Equations ....................................................... 247 Bit Weight Rotational Speed Equations ......................... 247 Bouyancy Factors ............................................................... 274 Casing Data, API ................................................................ 232 Casing, Dimensions ............................................................ 232 Casing, Eccentric Diameter ................................................ 214 Casings, Recommendations to Set Small Clearance Consecutive Strings ......................................... 93 Connection Interchange List, Rotary Shouldered ............... 262 Conversion Factors, English and Metric ............................. 290 Conversion Factors, Fraction to Decimal ........................... 289 Conversion Factors, Hardness ........................................... 286 Conversion Factors, Mud Weight ....................................... 149 Drill Collar Weights ............................................................. 271 Drill Mill Specifications .......................................................... 53 Drill Pipe Data ..................................................................... 266 Drill Pipe Data, Hevi-Wate .................................................. 267 Drilling Fluid Property Equations ........................................ 251 Drilling-Type Underreamer Specifications (DTU) ................ 115 DTU Underreamer Cone Availability ..................................... 89 Dull Bit Grading, IADC ........................................................ 244 Duplex Mud Pump Data ..................................................... 275 Eccentric Diameter, Casing ................................................ 214 Economill Specifications ....................................................... 52 Econo-Stock, Retrievable ..................................................... 70 Equations, Hydraulic Calculation ........................................ 248 Gauge Diameter Tolerances Hole Openers/Hole Enlargers 157 Gauge Diameter Tolerances Underreamers .................. 132 GTA Hole Opener Specifications ........................................ 181 Hardness Conversion Table ............................................... 286 Hardness Impression Diameter .......................................... 287 Hevi-Wate Drill Pipe Data ................................................... 267 Hole Enlarger Specifications .............................................. 203 Hole Opener, GTA Specifications ....................................... 181 Hole Opener, Master Driller Specifications ......................... 163 Hole Opener, Net Annular Area Removed .......................... 140 Hole Opener, SDD Specifications ....................................... 171 Hole Openers/Hole Enlargers, Gauge Diameter Tolerances ..... 157 Hole Openers/Hole Enlargers,

Index of Product References

Weights and Rotary Recommendations ......................... 156 Hydraulic Calculation Equations ......................................... 248 Hydraulic Tool Flow Rate, Minimum ................................... 138 Hydraulic Tool Opening Force ............................................ 137 Hydraulic Tools, Jet Combinations ..................................... 148 IADC Dull Bit Grading ......................................................... 244 Impression Diameter, Hardness ......................................... 287 Jet Combinations for Hydraulic Tools ................................. 148 Jet Nozzle Area .................................................................. 148 Junk Mill Specifications ........................................................ 43 Junk Sub Specifications ....................................................... 45 Junkmaster Specifications .................................................... 55 K-Mill, Casing Specifications ................................................ 14 K-Mill, Flow Rates ................................................................... 9 K-Mill Specifications ............................................................. 14 Makeup Torque, Recommended Minimum ......................... 254 Makeup Torque, Top Sub .................................................... 264 Marine Pipe Cutter, Cutter Length Specifications ............... 220 Marine Pipe Cutter, Flow Rates .......................................... 209 Marine Pipe Cutter, Specifications ...................................... 218 Marine Support Swivel, Specifications ............................... 223 Master Driller Specifications ............................................... 163 Milling, General Operating Recommendations ....................... 5 Milling, Normal Rates ............................................................. 5 Mud Pump Data, Duplex .................................................... 275 Mud Pump Data, Triplex ..................................................... 282 Mud Weight ........................................................................ 149 Mud Weight, Bouyancy Factors .......................................... 273 Mud Weight, Conversion Factors ....................................... 149 Net Annular Area Removed with Underreamer or Hole Opener ......................................... 140 Nozzle/Orifice Area ............................................................. 151 One-trip Trackmaster ............................................................ 74 Orifice Sizes for Drilling-Type and Reammaster ................. 143 Orifice Sizes for K-Mill, SPX/Drag- and Rock-Type ............ 144 Pack-Stock, Retrievable ....................................................... 65 Pilot Mill Specifications ......................................................... 32 Pipe Cutter, Cutter Length Specifications ........................... 220 Pipe Cutter, Flow Rates and Rotary Speeds ...................... 209 Pipe Cutter, Specifications .................................................. 219 Pressure Drop Across One Orifice ..................................... 146 Reamaster Operating Parameters ........................................ 94 Reamaster Underreamer (XTU) Specifications .................. 105 Retrievable Anchor-Stock ..................................................... 67

Index of Product References

Retrievable Econo-Stock ...................................................... 70 Retrievable Pack-Stock ........................................................ 65 Rock Bit Comparison Chart ................................................ 234 Rock-Type Underreamer (RTU) ......................................... 123 Rotary Shouldered Connection Interchange List ................ 262 RTU Underreamer Cone Availability ..................................... 89 SDD Hole Opener Specifications ....................................... 171 Section Mill, Flow Rates ......................................................... 9 Section Mill Specifications .................................................... 27 Servcoloy Composite Rod .................................................... 59 Servcoloy Concentrate Rod .................................................. 59 Servcoloy S Field Kits ........................................................ 60 Skirted Junk Mill, Specifications ........................................... 55 Small Clearance Consecutive Strings of Casings, Recommendations ............................................. 93 Spacer Sub Length Sizing .................................................. 212 SPX/Drag-Type Underreamer Specifications ..................... 131 Stabilizer Top Sub, Blade Diameters .................................. 220 Stabilizer Top Sub, Specifications ...................................... 219 Swivel, Marine Support Specifications ............................... 223 Taper Mill Specifications ....................................................... 51 Tool Joint Dimensions, Recommended Min-Max ............... 265 Torque, Recommended Minimum Makeup ......................... 254 Torque, Top Sub Makeup .................................................... 264 Total Flow Area (TFA) ......................................................... 223 Trackmaster .......................................................................... 74 Triplex Mud Pump Data ...................................................... 282 Tubing Data ........................................................................ 270 Underreamer, Cone Availability ............................................ 89 Underreamer, Drilling-Type (DTU) Specifications ................ 115 Underreamer, Net Annular Area Removed ......................... 140 Underreamer, Reamaster (XTU) Specifications ................. 105 Underreamer, Rock-Type (RTU) Specifications ................. 123 Underreamer, SPX/Drag-Type Specifications .................... 131 Underreamer, STU Makeup Torque Specifications .............. 99 Underreamer, XTU Makeup Torque Specifications .............. 99 Underreamers, Gage Diameter Tolerances ........................ 132 Washover Shoes, Specifications .......................................... 60 Weights and Rotary Recommendations for Hole Openers/Hole Enlargers ......................................... 156 XTU Underreamer Makeup Torque Specifications ............... 99