Recommended Practice: Window Milling: Mechanical Whipstock – Mill Single String Page 1 of 5

Alaska Drilling and Wells

Recommended Practice: Window Milling: Through Tubing
Mechanical Whipstock

Authority: Drilling Manager Custodian: Drilling Representative

Document
Control ADW Document Control
Scope: ADW – CTD Operations
Administrator Specialist
:
Alaska Drilling and
Issue Date: December 1997 Issuing Dept:
Wells (ADW)
Revision Date: June 10, 2003 Control Tier: Tier 4
Next Review Date: June 10, 2005

1.0 Purpose/Scope
Milling technique/parameters for 3-5/8” Baker through tubing whipstocks for 5-1/2” and 7”
liners.

2.0 Definitions
None

3.0 General Requirements

None

4.0 Key Responsibilities

- Baker TT representative and Wellsite Leader - Follow recommended practice for milling
window. Discuss any significant deviations with Anchorage.
- Drilling engineer – (not within scope of this milling RP) - pick proper whipstock location to
achieve directional objectives and avoid cutting casing collars. Assess casing integrity based on
log or well/field history prior to setting whipstock.

5.0 Procedure/Process

SCOPE AND BACKGROUND

One of the most crucial areas in CT sidetrack drilling is milling a smooth exit window in the
existing well. When the Baker thru-tubing whipstock was yard tested, a combination of milling
BHA’s were developed to make a starting hole and then enlarge the window. The current one
run milling technique includes a 3.80” OD HCC diamond speed mill and 3.80” HCC diamond
string reamer design, which has evolved through field experience.

The guidelines below outline the requirements for milling single or double walled casing
windows off of 3-5/8” Baker thru-tubing whipstocks set in 5.5” and 7” casing.

Control Tier: 4 – ADW Revision Date: 06/10/03

Document Number: UPS-US-AK-ADW-CTD-HSE-DOC-00008-4 Print Date: 06/10/03
PAPER COPIES ARE UNCONTROLLED. THIS COPY VALID ONLY AT THE TIME OF PRINTING. THE
CONTROLLED VERSION OF THIS DOCUMENT CAN BE FOUND AT http://alaska.bpweb.bp.com/ems
Recommended Practice: Window Milling: Mechanical Whipstock – Mill Single String Page 2 of 5

MOJ note on 6/6/03 – Since March of 2002 there have been 5 incidents of stuck BHAs while
window milling:

3/2002 – DS 1-19A had 2 stuck BHAs with the Baker 4 ½” x 7” Gen II. The first occurred after
the window was thought to be complete with 10’ of rathole, but after POOH, the NRJ had
parted. The BHA was found to be stuck during fishing and would not move (not recovered).
The second occurred after milling from pinch point down 4.5’ in 3 hours. A stall occurred and
the BHA never moved again despite heavy fishing. RDMO. CBL showed good cement behind
pipe. A 3rd window was successful in 11/2002 after cementing the whipstock in place and
milling in 2 runs (1st - window mill to cut window, 2 nd - window mill and string reamer to dress).

10/2002 – J-01A had 2 stuck BHAs with the Baker 4 ½ x 5 ½” Gen I. Both stuck pipe incidents
were identical in that 4’ of window was milled and a stall occurred. First PU was free. Eased
back down, stall again, and stuck. No BHA recovery despite heavy fishing. A 3 rd window was
successful using the 2 run technique as above.

6/2003 – MPL-01A had 1 stuck BHA with the Baker 4 ½” x7” Gen II. A drilling break
occurred at the bottom of the window and 3’ were drilled in a matter of 5 minutes, stall, stuck.
BHA never moved again. Decided not to fish based on history. Set another tray and
successfully milled using the 2 run technique as above.

Summary – Although the above stuck BHA incidents are not identical, it is believed that
contributing factors are rapid window milling with high WOB and motor work. Speculation at
this time is that thin metal edges may be pushed aside (rather than milled away) and then grab
the mill or reamer once an OD reduction occurs. As such, it is strongly recommended to control
drill the window and limit motor work to <400 psi differential to ensure the steel is milled
away. Also avoid rapid drill off at the bottom of the window. Control drill the first 4’ of
formation to avoid stall and allow the string reamer time to open and smooth the bottom of
window.

PRE-JOB PLANNING

The windows are usually milled with [ ½ -or 1 ] PPB Biozan water from the hot water plant and
high viscosity sweeps. Add shale inhibition (KCL and Kla-Gard) if kicking off in a shale.

15-20 Bbl, 2ppb Biozan or Flo-Pro high viscosity sweeps should be circulated at mid window,
BOW, and after drilling 10’ of formation. Circulate the wellbore to drilling mud prior to POOH
to avoid metal shavings being circulated through the drilling BHA MWD.

Always use 4 or 5 ditch magnets and the tiered magnet rack which should be cheeked and
cleaned regularly while milling. Do not run the centrifuge while milling. The centrifuge on
Nordic 1 is not designed for metal extraction and packs off if metal cutting are circulated thru it.
Ditch magnets should remain in use for all thru tubing CTD operations, in order to remove metal
shavings that will interfere with MWD tools.

Control Tier: 4 – ADW Revision Date: 06/10/03

Document Number: UPS-US-AK-ADW-CTD-HSE-DOC-00008-4 Print Date: 06/10/03
PAPER COPIES ARE UNCONTROLLED. THIS COPY VALID ONLY AT THE TIME OF PRINTING. THE
CONTROLLED VERSION OF THIS DOCUMENT CAN BE FOUND AT http://alaska.bpweb.bp.com/ems
Recommended Practice: Window Milling: Mechanical Whipstock – Mill Single String Page 3 of 5

GUIDELINES

The basic geometry of the 7” whipstock in relation to the window that is cut is as follows:

7 ” Whipstock Geometry
(not to scale)
0’ 2  Tray angle

4.6’ Casing contact - Pinch Point

Top of window, casing penetrated
5.5’ Formation contact

7.9’ Bottom of window

Total length is 17.5’ ”

“ RA ” tag is 10.0’ from the top
Windows are usually milled in one trip. When milling with 2-3/8” CT, add two joints of tubing
to the BHA to reduce the residual bend effect of the coiled tubing.

WINDOW MILLING BHA: BHA listed from the top down:

CTC, checks, 2 joints of 2 3/8” PH-6 tubing, Hydraulic disconnect, circ sub, 2-7/8”
Mud motor, 3.80” HCC Diamond String Mill and 3.80” HCC D0261 DSM.

A new 3.80” Diamond speed mill is used for each window, the 3.80” diamond string mill can be
used for several windows, just monitor the string mill for wear and gauge.

Depth Control
Depth control is one of the biggest challenges during window milling. The coil counter depths
can change significantly during the early stages of the operation. Initially, there will be an
apparent loss of hole due to the coil stretching from pumping and from overpulls after any stalls.
Counter slippage during frequent reciprocating can also cause measured depth confusion.

Prior to milling the window, the XN nipple is milled to 3.80”, while RIH with the window
milling BHA. Use minimum WOB and minimum motor work while milling the XN,
(approximately 0-100# WOB and 0-50 PSI of motor work ), to prevent backing off the 4-1/2”
tailpipe. This should not take long , ( 10-40 minutes ) and after a few passes are made, RIH dry
to make sure there is no longer a restriction. The XN should also be used for initial depth
control for CT measured depth. Use the corrected ELMD from the tubing tail and calculate the
corrected XN nipple depth, because the CTD window milling is tied-into ELMD. Note: The
XN depth on BP well schematics are always listed as drillers depth and need to be corrected to
ELMD.

Control Tier: 4 – ADW Revision Date: 06/10/03

Document Number: UPS-US-AK-ADW-CTD-HSE-DOC-00008-4 Print Date: 06/10/03
PAPER COPIES ARE UNCONTROLLED. THIS COPY VALID ONLY AT THE TIME OF PRINTING. THE
CONTROLLED VERSION OF THIS DOCUMENT CAN BE FOUND AT http://alaska.bpweb.bp.com/ems
Recommended Practice: Window Milling: Mechanical Whipstock – Mill Single String Page 4 of 5

WINDOW MILLING PROCEDURE

Typical practice to start window milling, is to RIH with minimum pump rate and lightly tag the
whipstock / liner pinch point. Pick up 10-15 ft, bring the rig pump on at 2.4 – 2.6 bpm and RIH
at 1 FPM, starting 5 ft above the previous tagged depth. Usually the pinch point will be found
about 2 ft. higher than the previous tagged depth. Typically, the motor will stall again, if so,
pick-up and RIH slower than the first time, looking for any motor work or WOB just above the
last stall depth.

Getting the DSM pattern started at the pinch point is slow, easy milling, usually 0.5 FPH for the
first 10 minutes.

Once steady milling is established, flag the pipe and measure the window milling progress from
this depth. This is considered the top of the window. Assuming that this is the point of casing
contact and not the top of the whipstock, then the window milling should start 1.2’ below the top
of whipstock in 5-1/2” liner and 4.6’ below the top of whipstock in 7” Liner. Typical window
milling rates are 1.0 – 1.5 FPH, with 400 psi motor work and 1000-3000 # WOB. When the mill
face is half way across the liner, ROP will slow and more WOB may be needed (maximum of
5000# WOB) to get past the mid point. This is due to the slow radial velocity of the mill at its
center.

If steady milling cannot be established then it is possible that the mill is still at the top of the
whipstock. This problem has mainly been corrected with the 0.75” taper on the OD of the HCC
DSM. Perform dry tags or tags at minimum rate to locate the whipstock top, if a depth control
question occurs.

WINDOW EXIT
When approaching the liner exit depth, control mill the window at 1.0 FPH. Limit motor work
to 400 psi. and reduce WOB to 1000 – 2000# WOB. Stacking excess WOB will cause the mill
to exit early and leave a lip at the base of the window in the liner, which is difficult to remove.

Due to mills stalling and sticking at the exit point, the present recommended procedure is to time
mill the last 2 ft of window at 1 fph, prior to the expected exit point. The first 4 ft of formation
should also be time milled, but at 2 fph, to allow the diamond string reamer time to ream the
window exit area.

Mill 10 ft of formation if possible. Back ream the window and ream down at least three times,
while swapping the well over to the FloPro drilling fluid. Stop pumping and RIH thru the
window to TD and confirm the window is clean. Ream the window again if a weight loss is
seen.

WINDOW MILLING NOTES:

The coiled tubing flag will not be on depth, if a second trip is made in the hole, because the coil
may have some residual bend again. The coil may also be permanently elongated by 1 –2 ft.
between runs.

For the 7” window milling, the initial point of casing contact is 4.6’ down on the whipstock.
From this point, the length of whipstock tray is about 6’. Therefore, about 6’ - 8’ of window
should be milled, to fully exit the liner with the mill. Generally, a 6 - 8’ window and 8’ to 10’ of
open hole is considered acceptable. For low side windows, the mill will typically exit the liner
early at 5-6 ft.

Control Tier: 4 – ADW Revision Date: 06/10/03

Document Number: UPS-US-AK-ADW-CTD-HSE-DOC-00008-4 Print Date: 06/10/03
PAPER COPIES ARE UNCONTROLLED. THIS COPY VALID ONLY AT THE TIME OF PRINTING. THE
CONTROLLED VERSION OF THIS DOCUMENT CAN BE FOUND AT http://alaska.bpweb.bp.com/ems
Recommended Practice: Window Milling: Mechanical Whipstock – Mill Single String Page 5 of 5

The concave face of the D0261 mill will help keep it from jumping out too early. After milling
5 ft of window, reduce the WOB to reduce the possibility of an early exit, because it is very
difficult to lengthen the window once it has been milled.

It can be tough to get the mill started. One technique that has worked is to park just above the
stall point and gradually increase the rate. The milling and motor work begin as the pipe
stretches and contact is made.

Once over the initial stalls, then steady milling progress can be made. Control mill the window
with no more than 400 dp motor work and minimal WOB if possible.

Loading on the hydraulic disconnect and motor can be quite severe. Motor shafts have failed in
the past. Keeping stall pressures under 500 psi and shutting down to pick up can help reduce
motor shaft fatigue.

6.0 Key Documents/Tools/References

Revision Log
Revision Date Approving Custodian/ Revision Details
Authority Author
December 1997 Original Issue
March 31, 1999 Drilling Manager John McMullen

June 10,2003 Paul Hyatt Mark O. Johnson Revise to reduce stuck BHA
occurrences
<< Revision date >> << Approving << Author’s << Brief Description of Revision
Authority’s Name >> Name >> >>

(or, see attached e-mail )

Approving Authority signature Date

Control Tier: 4 – ADW Revision Date: 06/10/03

Document Number: UPS-US-AK-ADW-CTD-HSE-DOC-00008-4 Print Date: 06/10/03
PAPER COPIES ARE UNCONTROLLED. THIS COPY VALID ONLY AT THE TIME OF PRINTING. THE
CONTROLLED VERSION OF THIS DOCUMENT CAN BE FOUND AT http://alaska.bpweb.bp.com/ems