IADC/SPE 59237
Milling Variable Window Openings for Sidetracking
Praful C. Desai, SPE, Smith International, Inc, and Charles H. Dewey, SPE, Smith International, Inc.
Copyright 2000, IADC/SPE Drilling Conference
This paper was prepared for presentation at the 2000 IADC/SPE Drilling Conference held in
New Orleans, Louisiana, 2325 February 2000.
This paper was selected for presentation by an IADC/SPE Program Committee following
review of information contained in an abstract submitted by the author(s). Contents of the
paper, as presented, have not been reviewed by the International Association of Drilling
Contractors or the Society of Petroleum Engineers and are subject to correction by the
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Abstract
Historically, the profile of the window milled with a
conventional whipstock system resembles an inverted tear
drop shape. The resulting full gage window opening is
relatively cramped for subsequent drilling assemblies and liner
completions. For example, in 7 casing the total window
opening is usually 10 feet long out of which only about 2 feet
of the opening has full diameter access for drilling and
completion tools.
This paper presents a unique whipstock design and milling
tool design, the combined performance of which produces a
full gage window opening of up to 85% of the total window
length and thereby provides an abundant clearance for drilling
assemblies and liner completions. Test conducted on 7-29
lbs./ft. casing resulted in a total window opening of 9.8 feet
(118) out of which 7.5 feet (90) was a full gage 6.00
opening. Test on 9-5/8-47 lbs./ft. casing produced 16.83 feet
(202) total window length of which 14.50 feet (174) of the
opening measured full gage width of 8.50.
The whipstock can easily be modified to produce the
desired length of full gage opening. Optionally, the window
can be milled without the need for drilling a rat hole.
The benefits of a longer full gage window are (1) trouble
free entries and re-entries through the window for drilling and
completion of lateral, (2) ideal for short radius departure, (3)
allows sidetracking in hard formation without drilling rat hole,
(4) compensates for any mismatch in depth tally calculations,
and (5) eliminates problems associated with skewed window
(longer full gage window is vertically straight).
The paper details the test set up, test results, photograph
and profile of actual milled windows and summarizes field run
results.
Introduction
The conventional whipstock systems, currently in use, require
single or multiple trips downhole to mill an appropriate
window for sidetracking the well. In all cases, the whipstock
includes a 1-1/2 to 3 degree tapered ramp, the length of which
varies from 8 ft. to 18 ft. depending upon the casing size and
manufacturer. The face of the ramp incorporates a concave
profile to facilitate the guiding of the milling tool.
In multiple trip operations, a starter mill is used to make
the initial cut out followed by a window/watermelon mill
combination milling tool which usually finishes the window.
In a single trip operation only one milling tool is used to
complete the window. In either case, the profile of the window
looks like an inverted tear drop as shown in (Fig. 1). This
shape is produced by milling the window using a continuous,
single angle whipface.
The full gage opening required for the subsequent drilling
assemblies is usually less than 25% of the total widow length.
This relatively cramped opening becomes more hazardous due
to the jagged edges of the window resulting from the rough
downhole milling operation. The BHA and completion
equipment, particularly the packers may get tangled and
prematurely damaged. In many cases, it may require
additional reaming trips with a watermelon mill to elongate
and smooth out the window profile.
The above described systems have been in use for many
years. The design of the whipstock and the milling tools were
derived from the earlier versions of remedial tools. Relatively
shallow 1-1/2 to 3 degree tapered ramps on the whipstock face
were designed to generate gradual milling torque on the casing
and to minimize the damage to the whipstock. Different shape
mills were designed and run to elongate and dress the window
to reduce the damage to the drilling and completion
components. However, there were no serious attempts made to
completely alter the window profile to eliminate potential
damage to other components while passing through the
window until now.
Not many years ago, development of multilateral
technology began as a method for improving production from
oil wells. Due to the vast expansion in multilateral activity,
more sidetracking systems are being used than ever before.
Prior to this time, whipstocks were permanently set in well
bores for getting around an unretrievable fish or section of bad
hole and for creating a kickoff point at the bottom of a bore
2 PRAFUL C. DESAI, CHARLES H. DEWEY
hole. In these cases, the whipstock is never removed and stays
aligned with the window, thus somewhat reducing potential
problems with tripping through the window. However, many
problems persisted and were even magnified as re-entry after
the whipstocks retrieval became a requirement.
The proliferation of multilateral drilling and completion
practices forced us to take a fresh look at the conventional
methodology of window milling. Our first step was to review
the interaction between the whipstock, the milling tool, the
casing and the formation and identify problems associated
with the conventional system. Once these problems were
identified and verified, our next step was to develop a new
system that would provide solutions to these problems and
offer a milled window suitable for multiple entries without
obstructions.
Problems Associated With Conventional Systems
The conventional system consists of a whipstock with a 1-1/2
to 3 degree single ramp and a cylindrical shaped lead mill with
a relatively flat bottom (Fig. 2).
1. Inconsistency In The Shape And Location Of The Full
Gage Section Of The Window. During the earlier part of this
downward travel, the mill is making the initial cut into the
casing. The force exerted by the casing on the mill is at its
highest level.
The force exerted by the casing on the mill transfers to the
whipstock and the cylindrical shape square bottom mill
sometimes tends to mill up the whipstock more than the
casing. If the whip face remains undamaged from the milling
operation, the location of the full gage section of the window
will be approximately 1/4 of the window length from the top.
If the whipstock backing is damaged and partially gone, the
mill has to travel downward even further to make the full gage
window. The location of this full gage section of the window
varies depending upon the condition of the whipstock and
whether the mill is full gage or undergage.
2. The Mill Progress Slows As The Mill Center Passes
Across The Casing Wall. The milling progress slows
considerably when the mill center reaches the casing wall. At
this stage the energy imparted by the mill on the casing is
minimized due to relative slow speed of the cutting structure
at the center of the mill. Therefore, additional maneuvering of
the drill string, such as additional weight and change in rotary
speed, is required to get the mill to progress down the
whipstock. This manipulation may continue for as much as 24
inches of downward travel of the mill. During this time,
penetration rates can reduce to a fraction of normal milling
rates. From this point on, the gage of the window starts to
rapidly close in because the mill is moving into the formation.
3. Deviation Of The Window. Window deviation is a
common problem in many windows milled with conventional
systems. Deviations in the window occur because the
combined forces exerted on the mill as it progresses change
throughout the milling process.
IADC/SPE 59237
In general, the top of the window will deviate to the left
side of the whip face. This problem is created by the forces
acting on the mill as it begins to cut into the casing. In most
systems, by design, the mill is very aggressive to the casing
while the whip is protected.
Once the mill has broken through the casing wall, the
forces pushing the mill to the left begin to reduce. At this
point, the window comes in line with the whip face. The
milled window remains fairly straight from this point down to
approximately half way down the whip face.
Here, several parameters controlling the mill direction
begin to change. The center of the mill is moving through the
wall of the casing. Mill progress often slows and more weight
is applied to push the mill past this point. Also, as the center
of the mill passes through the wall, the mill becomes unstable
and unsupported. The majority of the mill is outside the
casing and into the formation
4. Formation Imposed Limitations. In most cases the mill
fails to make rat hole in hard formation. The carbides used for
mill dressing are a metal cutting grade of carbide and not
compatible for drilling formation. In most cases with hard
formation, the mill never gets off of the whipstock and gets
stuck between the formation and the whip. If the mill is
progressing along this path, then the stresses in the assembly
become extremely high. Rotation for an extended period of
time in this situation will cause the threaded connection or the
mill mandrel to fatigue and results in premature failure. In
general, if the formation is harder, the mill will walk to the
left. The mill can be severely damaged and lose its ability to
progress. It may also continue to mill the whip and casing
below the original whip face.
If the formation is soft, the window tends to deviate to the
right. In this case the toughest material in contact with the
mill is the whip and casing, causing this right hand deviation.
In addition to deviation to the right, the mill may be free to
move completely out into formation, a condition commonly
called jumping the whip. If this occurs, the window will be
shorter than anticipated.
On a few occasions, the window will be straight at the
lower end. In these cases, the stresses imposed on the mill by
the formation, casing, and whip are somewhat equalized,
producing a mill path with little or no deviation.
Objectives For New System
Taking all of the above problems into consideration, a new
sidetracking system was developed with the following
objectives; (1) predictable and consistent shape of the window,
(2) longer full gage window, (3) eliminate mill coring and
slow progress problems at the center of the whip, and (4)
formation specific mills.
To achieve these goals a special whip face was designed
that would rapidly place the milling assembly in the proper
location for producing the maximum width window. Then,
once in this position, the mill is allowed to progress parallel to
the casing axis to achieve the desired full width window. One
interesting fact is that the milled window is always
IADC/SPE 59237 MILLING VARIABLE WINDOW OPENINGS FOR SIDETRACKING
consistently straight when milling at the maximum width.
In medium to hard formations where crushed carbide mills
are not very effective, a special mill dressed with PDCs was
developed to run in conjunction with the new whip. These
PDC inserts are a modified grade capable of milling the
window and penetrating the formation.
In very hard formations, the whip can be designed so that
minimum departure of the mill is maintained while the
maximum width window is produced. This condition makes it
highly unlikely that the mill will contact the formation, thus,
reducing damage to the mill. A deflector can then be put into
position and a bit for drilling formation used to drill the rat
hole and the subsequent lateral.
Description of New System
The new system consists of a whipstock with multiple ramps,
each with different taper, and a milling tool with a conical
shape lead mill having small gage contact (Fig. 3).
The system profile contributes to a long full gage, full
width window as follows.
1. The whipstock incorporates a 15 degree ramp at the top.
There is a matching 15 degree taper on the lead mill. The mill
also has a short gage contact above the taper. As the weight is
applied, the mill engages with the casing and creates a quick
cut out. The quick cut out results from the fact that the stress
between the casing and the mill is much higher (due to small
gage contact) than the stress between the mill and the
whipstock (the matching 15 degree tapers are engaged). This
cut out is further aided by the fact that the whipstock material
is much harder than the casing. In the end, the casing, being
the weakest among the three, yields to the mill progress. The
quick cut out continues as the mill slides down the 15 degree
ramp. When the mill reaches the end of the 15 degree ramp,
the lateral travel by the mill is sufficient to create the full gage
window (Fig. 4).
2. The initial 15 degree ramp is followed by a zero degree
ramp, meaning the whipstock face is vertical. The window,
which is already a full gage window, is elongated as the mill
slides along the vertical face of the whipstock. The vertical
face of the whipstock can be as long as necessary depending
upon the size of the casing and the requirements of the well.
The length of the window can be adjusted by changing the
length of the vertical face on the whipstock.
3. At this point, the whip can be manufactured in one of
the following two ways.
(a) The first method would be of the type that does not
push the mill into the formation. This design is used
when the formation is hard to drill and a mill could
not get into the formation in good shape. With this
method, a very large full gage window is created,
leaving abundant room for running a drilling deflector
so the lateral can be created. On this whipstock the
final two ramps are 1 degree and 15 degrees
respectively. The 1 degree ramp is for blending the
whip face and the 15 degree ramp acts as a stop for
downward travel of the mill.
(b) The second method would be the type that pushes the
3
mill into the formation for the purposes of creating a
rat hole. The drilling of the lateral and running of the
liner can take place with the whipstock left in place.
On this whipface, the straight section of the whip is
followed by a 3 degree or more section which pushes
the center of the mill towards the wall of the casing.
As the center of the mill approaches the wall of the
casing, a 15 degree ramp is used to accelerate its
progress to the outside of the casing. The angle of the
whipface then reverts back to the typical ramp angle.
Notice that with the designs discussed above, the distance
required for the mill to cut out of the casing is minimized, thus
reducing the window deviation to the left. The next major
factor is that, for the majority of the milling operation, the
center of the mill remains inside the casing, thus no slow
down occurs during the milling operation. For this reason,
coring problems are also eliminated. Lastly, since the majority
of the mill remains inside the casing for all or most of the
window milling operation, the tendency for deviation to the
left or right due to formation characteristics is drastically
minimized.
Testing
The objective of these tests was to create a longer than
conventional casing exit that would allow substantial
clearance for subsequent drilling assemblies and completion
equipment.
The objective was to be achieved by milling long full gage,
full width windows without the mill departing in to the
formation and without the rat hole. The whipstock would be
retrieved and a deflector run for supporting various drilling
assemblies and completion equipment.
Two tests were carried out in a test facility to validate the
design criteria. (1) 729 lbs./ft. L-80 casing, and (2) 9-5/8
47 lbs./ft. L-80 casing
The test equipment included a rail supported horizontal
concrete block (30 x 36) created around a 40 foot long
casing joint (Fig. 5). The power was supplied by a low speed,
high torque multiple stage mud motor hooked up to a flow
loop capable of circulating up to 500 GPM. The motor was
positioned in a fixture with a ram that was capable of pushing
and pulling up to 120,000 lbs. of force.
The BHA consisted of an appropriate anchor assembly,
extended gage whipstock, milling tool with conical shape lead
mill (attached to the whipstock by a shear bolt), a joint of drill
pipe, cross over sub and the motor.
The ram was used to push the BHA in to the casing. After
confirming the proper orientation of the whipstock, the anchor
was set and the shear bolt was sheared to disconnect the
milling tool from the whipstock. The circulation was turned on
and the milling commenced.
There were several challenging situations that occurred
during the test program. However, they were of minor nature
and were resolved in time to continue the tests.
The concrete blocks were sawed in half after the tests to
expose the window profile (Fig. 6). The window
measurements were taken and recorded.
4 PRAFUL C. DESAI, CHARLES H. DEWEY
Test Results
The test results were as follows:
1. 7 29lbs./ft. L-80 casing. The lead mill used in this test
was dressed to 6.00 diameter. Total window length measured
118. The full gage of 6.00 on the window was from 68 to
158 for a length of 90 (Fig. 7).
2. 9-5/8 47lbs./ft. L-80 casing. The lead mill used in this
test was dressed to 8.50 diameter. Total window length was
202. The full gage of 8.50 on the window was 174 long
(Fig. 8).
Field Runs
The above described tests included a whipstock and a milling
tool design that would mill a relatively oversized window.
Modified designs of the system were used in the field to mill
full gage, full width windows that are at least two to three
times longer than the conventional window. Six jobs have
been run with varying degrees of window lengths depending
upon customers preference.
The most notable run was with the Drill Ahead System in
Oman in August of 1999. The Drill Ahead System consisted
of a modified whipstock and PDC mill made up on a motor
with a 1.4 degree bent housing. In a single trip, the casing was
sidetracked and the same assembly continued to drill ahead for
over 300 feet before it was pulled. The elongated full gage,
full width window allowed easy entry for the BHA consisting
of a PDC mill and the motor with a bend. This system is
discussed in detail in the SPE Paper #59185 (New Orleans
2000). One of the most notable aspects of this job was the fact
that a single milling unit produced an accessible window when
run on the modified whip. Reentry of subsequent drilling and
completion BHAs was found to be without problems.
The same concept was adopted in tools designed for
sidetracking with coiled tubing. In coiled tubing applications,
one of the major problems is the stiff BHA consisting of the
motor and the mill. The problem was overcome with the
elongated window profile. The initial 15 degree ramp on the
whipstock allowed quick departure for the mill. Once the
resistance from casing was overcome, the window was
elongated by the zero degree ramp which required relatively
less energy and the resulting window was long enough for the
stiff BHA to pass through easily.
Our records indicate that four jobs were successfully
completed in small casing. Each job was completed in a single
milling trip. The total milling time was 8 hours, 6 hours, 2
hours, and 3 hours respectively.
Future Considerations
Further modifications of the above described system will
make it possible to achieve the following objectives.
Window reentry possible without the use of casing
collars or permanent packers.
Customized window profiles that could interact with
other well components used during completion and
reentry.
Technically advanced whipstock systems that will
IADC/SPE 59237
produce full-length, full-gage windows followed by a
rat hole drilling operation in one trip.
It can be seen that the window could easily be customized
simply by modification to the whip face. One other advantage
to this type of milling system is that the window should be
very straight due to the fact that the majority of the mill
remains inside the casing for all or most of the milling
operation.
The predictability of window shapes produced from this
system will make future well operations much more reliable.
Conclusions
Windows milled by conventional whipstock systems basically
resemble an inverted tear drop shape. The full gage, full width
opening however is approximately 25% of the total length.
Above and below this section, the window size and deviation
is very unpredictable. This relatively cramped opening,
surrounded by unpredictable window shapes, presents
problems for drilling assemblies and completion equipment.
The whipstock system described in this paper is capable of
milling a long window with up to 85% of its length providing
full gage, full width opening. Big openings such as this
provide abundant clearance for drilling assemblies and
completion equipment.
The new whipstock system can also be used to mill long
full gage, full width windows without the rat hole. This
feature is desirable in two cases. One case is where the
formation is hard and not friendly to the mill dressed with
crushed carbide. The other case is where the drilling objective
requires short radius departure for the drilling assemblies.
Acknowledgements
The authors wish to thank Smith International, Inc. for
permission to publish this paper. The authors would also like
to thank Ronald Childers for coordinating the tests, Lane
Lancaster for creating the graphics and Beverlyn Bankes for
assistance with formatting the paper.
References
1. Dewey, C., and Childers, R.D.: Planning for Successful
Window Milling Operation, paper SPE 49255 presented at the
1998 SPE Annual Technical and Exhibition, New Orleans, LA,
27-30 September.
2. Miller, G., Dewey, C., and Saylor, J.: Sidetracking in a Single
Trip, paper SPE/IADC 37665 presented at the 1997 SPE/IADC
Drilling Conference, Amsterdam, The Netherlands, 4-6 March.
3. Childers, R.D., and Miller, G.: PDC Technology Advances
Sidetracking Capabilities, paper SPE 59185 presented at the
2000 IADC/SPE Drilling Conference, New Orleans, LA, 23-25
February.
IADC/SPE 59237 MILLING VARIABLE WINDOW OPENINGS FOR SIDETRACKING 5

Figure 1: Window Profile using Conventional Sidetracking System Figure 2: Conventional Sidetracking System
6 PRAFUL C. DESAI, CHARLES H. DEWEY IADC/SPE 59237

Figure 4: Window profiles using New Sidetracking System

Figure 3: New Sidetracking System
IADC/SPE 59237 MILLING VARIABLE WINDOW OPENINGS FOR SIDETRACKING 7

Figure 5: Test set up

Figure 6: Sawed-off concrete block exposing window

downhole
15
Csg. OD
2"left
1" left
10
high side axis
1"right
2" right
Csg. OD
5
59 74 89 104 119 134 149 164 179 194 209 224 239 254 266

High Side Axis (inches)

downhole

csg. OD
15 Smith Whip Tip
2"left
1" left
10 high side axis
1"right
2" right
5
Start of Full Gauge
csg. OD End of Full Gauge
SSDS Washover Whip Tip
0
40 50 60 70 80 90 100 110 120 130 140 150 160 170
Figure 7: 7-5/8 Casing Window Profile
High Side Axis (inches)

Figure 8: 9-5/8 Casing Window Profile