Under-Reaming & Milling With CT

Recommended Practice: Under-reaming and Milling Page 1 of 20
Alaska Wells Group

Recommended Practice: CTU Operations - Under-reaming and
Milling
AK, D&C Well Services AK, D&C Wells CT

Authority: Custodian:
Operations Team Lead Scheduler
Document Control Document Control
Scope: Wells: Coiled Tubing
Administrator: Specialist
Alaska Wells Group
Issue Date: January 22, 2002 Issuing Dept:
(WELLS)
Revision Date: May 28, 2010 Control Tier: Tier 4
Next Review Date: May 28, 2013
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1.0 Purpose/Scope
This section provides a discussion about milling and under-reaming using coiled tubing. It offers
recommendations for planning and supervising milling and under-reaming operations by the Well
Site Leaders of the North Slope.
Note: Section 10.0 contains Lessons Learned from the field.
2.0 Definitions
CTU – Coiled Tubing Unit
WSL - Well Site Leader
3.0 General Requirements

This section provides recommended procedures for planning and conducting milling and under-
reaming operations using coiled tubing on the North Slope.
4.0 Key Responsibilities

Well Operations Supervisor is:
 To designate the person to update manual as necessary to incorporate new policies or
procedures
Well Site Leaders are:

 Responsible for identifying and submitting changes to the procedures and methodology
based on new technology and new and better ways of performing work
 Update the manual based on changes as a result of Root Cause Investigations
5.0 Procedure
5.1 Introduction
Under-reaming, milling, or drilling with low torque, positive displacement mud motors (PDM)on
coiled tubing has been successful in cleaning out cement, hard fill, junk, and other objects left in
a well. The motors operate by fluid passing through the motor stator which requires a certain
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minimum differential pressure and flow rate to effectively rotate the shaft and bit below the
motor. By applying weight to the bit, drilling gradually removes the solid material.
Under-reaming is a cost effective method to clean out the production casing or liner. The
common application for under-reaming is to remove cement left from squeeze operations. In
many instances, large cement nodes form at the squeezed perforations or a cement sheath will
be left in the casing. These restrictions must be removed to allow future operations. An
underreamer may also be used to remove scale sheaths from casing, hard fill that cannot be
removed by jetting with a CT nozzle, or cement caps that were intentionally placed on top of
sandbacks. By choosing the appropriate underreamer size, the casing can be cleaned out to its
original ID – even though the tools must pass through production tubing and other restrictions
before reaching the casing/liner.
While a bit or mill could be used in these instances, the resulting hole size from a mill would be
approximately the same size as the tubing ID, leaving a thick sheath on the walls of the larger
OD liner. This sheath can break up during subsequent operations, such as perforating, and
possibly stick the tools.
Milling is primarily used to clear scale from tubing or clean out cement when liners are smaller
OD than the tubing, i.e. coiled tubing sidetrack wells. In addition, milling can be a useful tool in
removing restrictions or tools that cannot be fished. Examples would be increasing the ID of an
XN nipple or milling up a lost tool in the well that could not be fished. Milling a window for
sidetrack drilling is sometimes performed. This operation is discussed in “Window Milling with
Coiled Tubing” section.
5.2 Special risk factors

 Cement: for set cement, only Geovis XT mixed in KCL is recommended; other biopolymers
are seriously degraded. Geovis XT made with 2% KCl has been proven in the lab to not be
effected by set cement up to 230F. See the CT Fluids RP for more information.
 Slim holes: milling in 3-1/2” tubing with a 2-7/8” motor results in extremely small annular
clearance. Stuck pipe is much more of a concern, so be extra conservative
 Barium Sulphate scale milling: cement and sand are 2.65 sg. Barium sulphate scale is
3.95 sg! Even more intimidating is to compare the difference in sg to water: sand/cement is
1.95  sg, and scale is 2.95 sg. Every thing else being equal, a scale particle will fall
through water 79% faster!
5.3 Tool Descriptions

5.3.1 Underreamer
The underreamer is designed to pass through tubing and open up below the tubing tail in larger
ID pipe. It can clean out the casing to full drift ID. The underreamer arms retract when retrieved
from the hole.
Different blade sizes and types are made for various tubing and casing combinations. Contact
service company personnel for available underreamers. Discuss the situation with the Well
Operations supervisor as well as the service company personnel. Remember – just because a
tool can satisfy the tubular combination on a well does not mean that it is a good idea to use that
tool. For example, there is an underreamer that can pass through 3-1/2” tubing and expand to
5.75” for cleaning out 7” casing. However, these underreamers have a history of breaking off
arms and leaving a fish in the hole. Underreamers for 9-5/8” casing also do not have a good
performance record.
There are several different types of underreamers available on the North Slope including the
Quesenbury, Reeves, and Baker models. Each type has a unique design. The diffferent
underreamers – like mills should be evaluated for the application.

Various underreamer brands and designs are available from the service companies on the North
Slope and are also used in numerous applications throughout the field. Once you have
determined the specific details of the operation, what is to be removed and maximum and
minimum ID, contact the service companies and solicit their recommendations.
5.3.2 Mill
A mill is a very simple drag type bit. It has a cutting structure and no moving parts. Mills are
manufactured in various shapes and designs for different applications. Mills can also be custom
built for a specific purpose in mind. Before building a mill for a specific purpose, check the
wireline building. There are various types and sizes of mills which have been built over the years
by the Well Site Leaders. If the proper size or type is not found, you may find a model or idea for
the current job. Many good previously used mills can also be obtained from CT Drilling. For the
purpose of this section, two basic shapes will be discussed, flat bottom and a tapered cone type.
Both types are ported to allow jetting and circulation.
A mill’s cutting structure is usually an abrasive face of tungsten carbide chips welded to the body
of the mill. Gauge protection is important to maintain the full hole diameter so the walls of the
mill often have tungsten carbide welded to the body and ground smooth. The mill is machined to
the correct gauge to prevent excess wear on tubulars.
The flat bottom mill can be used for cleaning out hard fill or cutting scale. They are also used to
mill up fish and can even be designed with a bevel towards the center to dress off the top of a
fish or keep the mill on top of the tool being milled.
The cone type mill is used to increase the ID of a restriction or mill a fish from the center out, as
in cases where the fish is broken up and the junk is just rotating on top of the fish. The cone type
of mill generally has a tungsten carbide abrasive cutting structure on the side of the mill with a
steadily increasing OD as you approach the pin end of the mill. The cone type mill can also be
used for cleaning out very hard scale restrictions.
Diamond bits have also been used for cleanouts of hard fill and drilling cement. The diamond
bits work well for cutting longer cement sections and hard fill. They may last several jobs. Check
with the various CTD units to see if a used mill may be available as the cost for a new mill is
high.
After you have determined the goal of the operation, contact the service companies to determine
the mill design options that are available. It may be necessary to have a mill made which may
take 24+ hrs so get input as soon as possible.
5.3.3 Motor
A positive displacement motor is used to rotate the underreamer or mill. When working through
tubing , consideration should be given to which motor size to use;
 For 5-1/2” and larger tubing/liner, 2-7/8” OD motors are recommended. This allows the tool to
pass through the 3.725” minimum restriction that is usually the minimum restriction for a 4-
1/2” completion.
 For 4-1/2” pipe, a 2-1/8” motor is fishable should something part. It might be best to try first.
If it is unable to accomplish the objective then a 2-7/8” motor can be used with the
understanding it is unlikely to overshoot.
 For 3-1/2” tubing a 2-1/8” motor is fishable, but if it won’t do the job then a 2-3/8” motor
(possibly not fishable) can be used. Although a 2-7/8” motor technically would pass, it is
definitely not fishable. Also, the smaller motor sizes provide more annular clearance and less
chance of getting solids stuck around the BHA. The disadvantages of a 2-3/8” motor is lower
circulating rate and twisting off of the shaft. One might still choose to use a 2-7/8” motor in 3-
1/2” liner for example, if there was 7” tubing at the top of the well to obtain sufficient pump
rate to transport the milled solids.
 For 2-7/8” tubing a 1.69” motor might be tried first, as it is fishable.

 For 2-3/8” liner, a 1.69” OD motor is the only choice.
The other consideration when choosing a motor other than OD is the tool size and type that is to
be run. If running an underreamer for 7” casing, larger motors have a bigger connection. The
more robust the connection the less chance you have of twisting off the underreamer.
5.3.4 Motor Head Assembly

A motor head assembly is run any time that a motor is run. The motor head assembly combines
the following tools:
- Coiled tubing connector

- Dual check Valves
- Hydraulic disconnect
- Circulation sub with a rupture disk
- Hydraulic Disconnect
A hydraulic disconnect should always be employed when under-reaming in the event the BHA
becomes stuck in the hole. Moreover, the disconnect should be rugged enough for under-
reaming and milling. Verify with the service company that the disconnect meets the severe
fatigue and torque conditions that under-reaming creates.
Circulation Sub and Burst Disk - Once under-reaming is complete, it is usually desirable to
increase pump rate to circulate solids to surface and cleanout the well. In order achieve a
circulation rate capable of removing solids, the motor and underreamer must be bypassed. The
circulating sub below the hydraulic disconnect provides this flexibility. By running the circulating
sub below the disconnect, the disconnect can still be used after the circulation sub is opened.
The burst disk is an emergency type component which is used in the event that you are unable to
circulate fluids and a ball to the circulating sub or hydraulic disconnect. The component, although
untested, is designed to shear out at differential pressure estimated to be 4500 psi. Check with
the service company that a burst disk is installed and the pressure rating of the disk.
Optional tools: Jars and accelerator: Jars provide a means to provide an impact to a BHA that
is stuck in an attempt to free the BHA. Jars are not usually run with a BHA that has a motor
because the addition of jars and an accelerator make the BHA too long to be covered with the
lubricator on many rig ups. On a well with severe doglegs, a long BHA can also prevent the bit
from getting to bottom. Jars in the BHA also move the circulation point about 6-8’ above the bit if
the bit is plugged and the circulation sub has to be opened. The advantage of running jars is that
it may save a fishing job if the coil is stuck by adding the potential to add impact to circulation
when trying to free the coil.
Optional tools: Motor partial bypass sub: If a small motor must be used for milling and the
maximum flow rate is not enough to adequately remove the milled solids, a fluid bypass sub can
be run above the motor. The sub splits the flow between the motor and the circulation port, thus
allowing higher overall pump rates down the coil while keeping reasonable pump rates through
the motor. The main disadvantages with the bypass sub are it becomes more difficult to detect
stalls and the maximum motor torque may not be able to be achieved with too much bypass.
6.0 Preparation
1) Review the well history and current production parameters thoroughly. Be certain that the
analysis of the problem and objectives of the program are clear. Download or prepare a
wellbore diagram that shows the following:
 Tubular – size and depth. Be sure that you know the drift of the tubulars as well as the
ID.
 Restrictions – ID and depth

 Perforations
 Depth to fish or obstruction. Nature of material to be milled or underreamed.
 Last tag depth by wireline or coil
 Caliper runs (scale milling)
2) Contact the service company that will supply the downhole equipment and discuss the job
with their representative. Provide the job details to the service company to make sure the
tools you are considering are the best choice for the job.
3) Choose type of mill/underreamer based on maximum OD allowed by completion and
physical material that will be drilled. Mills vary from those designed to cut metal to cement
or hard fill. For scale milling, select blades that are drift ID in diameter. This reduces the
lateral motion of the underreamer and stresses on the blades, as well as cleaning out the
pipe as well as possible. Experience shows you will only achieve an OD of the assembly and
little or no more. If the underreamer will not have a full liner ID location to open, ensure the
tool provider knows you will need to cut your way open.
4) Choose motor based on OD, torque and speed. Estimate the maximum pump rate and
pressure differential for the job. Ensure that the motor will function within the pump rates
and pressures that are anticipated for the job. With coil tubing friction losses, the most
limiting factor on motor selection is pump rates. In addition, you will need sufficient annular
bypass that removes solids keeping the tool unimpeded.
5) Make sure coil has been pigged with an equal or greater size ball than the ball for the
hydraulic disconnect. This pigging is required when a new coil reel is put in service and
immediately following any butt welds. If you are unsure if the pipe has been pigged properly,
allow time in rig up procedures for this activity.
6) Check all additional tools and threads. The coiled tubing connector, check valves, hydraulic
disconnect, circulating sub, and crossovers need to able to handle torsional loads, impact
loads, and vibration loads. Premium tools and threads are demanded for motor related work.
7) The ball size for the hydraulic disconnect should be checked. Make sure the hydraulic
disconnect ball is the largest ball used in configuration. Visually inspect that it is
appropriately sized for the seat and will physically pass through the connector and check
valves. Also check the ball size for the circulating sub and visually inspect that it is
appropriately sized for the seat.
8) Fluids used for the operation should consist of water as the power fluid and a 150,000 LSRV
gel as the sweeping fluid. Hot clean water, either fresh water with 2% KCl or seawater, is
available and is preferred for operations since it is non-damaging. Friction reducers should
be added to the water to reduce the pumping coil pressure, which in turn allows more room
for detecting potential stalls. A typical cleanout will require at least 2 to 3 hole volumes
(barium sulphate milling requires even more) so have tanks spotted on location. See the
Coiled Tubing Fluids section of the PE Manual for more specifics on fluids.
9) The cuttings must be removed from the wellbore if the operation is to be a success. Use a
high viscosity fluid such as Biozan, Flo-Pro or Geovis XT to lift the solids off bottom and out
of the hole. You will need to suspend the solids and maintain a fluid velocity up the wellbore
greater than the solids settling velocity to have efficient wellbore cleaning. (Settling velocities
are discussed in the Fill Cleanout Section. There is a spreadsheet on the Wells Group
Website that calculates particle settling velocity)
10) Put the well on production if possible and use lift gas when available. Returns during the job
can be taken to the flowline if there are minimal solids drilled (<100 ft) with small volumes of
Biozan. Otherwise, returns must be taken either to an open top tank for non flowing wells or
through a flowback separator with gas going to the system and liquid to a tank.

6.1 Recommended Equipment

The following equipment is recommended for a milling or under-reaming job using coiled tubing.
6.1.1 Milling with returns to the system:

 Pump-in sub with backside line.
 Reverse-out skid (so that you can pump down backside, coil or both)
 Upright(s) with enough fluid to circulate well 3 times. Fluid should be either 2% KCl or
seawater. Add 1 gallon of friction reducer per 1000 gallons of water (double slick)
 Biozan, Flo-Pro, or Geovis XT (plus vac truck or upright for storage).
 BHA – Motor Head Assembly (Connector, Dual Checks, Hyd Disconnect and Circ Sub)
 Motor
 Mill or Underreamer.
 Optional – jars and accelerator
 If cold weather
- Methanol tanker
- Methanol approved triplex pump
- Neat methanol trailer
- Heaters
6.1.2 Milling with returns to tanks:

All the equipment for a normal cleanout to the system PLUS:
 Choke manifold
 Tiger tank (minimum of one)
 Open top tank (minimum of one)
 Secondary Containment for flowback tanks
 ASRC test separator. This is required if working on a live well in some field areas depending
on the ability of the plant to handle returned gel and solids.
 ASRC Flow Cross (if using separator)
 Temporary flowline to an adjacent well tree cap for gas returns (or a flowline cosasco valve if
adjacent wells are unavailable.)
7.0 Execution
1) Rig up the CTU per the standard rig up procedures. Ensure some coil is cut off the end if the
reel was just used for a milling job previously, due to coil fatigue. Pick up the motor head
assembly (MHA consisting of connector, dual checks, hydraulic disconnect and circ sub).
Measure and record the OD, ID, and length of each component. Drift the MHA with the ball
for the hydraulic disconnect. Each part of the assembly should be thread locked and made
up with the correct torque. With high rotating speeds, spin-offs can occur if connections are
not made up properly. The MHA should be made (through the circulating sub) and pull tested.
Pressure test the MHA to 4000 psi through the coil tubing prior to picking up the motor and
underreamer.
Once the MHA is pressure tested, pick up the motor and mill. Measure and record the OD, ID
and length of each component. Record the size ball for the disconnect and circulating sub.
Record the size and type of the fishing neck for the disconnect. If running an underreamer,
after making up the underreamer, tape the underreamer arms together (if the design calls for
it) and raise it into the lubricator.
It is preferable to perform the pressure test of the stack and lubricator by pumping through
the pump in sub and coil instead of through the coiled tubing alone. If running an
underreamer, pressure test the lubricator and BOP by only pumping through the pump-in
sub. Limit the test pressure to 3500 psi (or the service company’s max collapse pressure).
Pumping through the coil may open the underreamer arms causing it to hang up in the tree

or on restrictions in the well. Be mindful of collapse pressure on the coil when pressure
testing through the pump in sub only. Bleed off pressure from the lubricator slowly to prevent
opening the underreamer blades.
If running a mill, it is a good idea to have one of the crew listen for the motor turning during
the pressure test.
2) After the pressure test, run the coil to bottom with the well flowing or shut in, depending on
well conditions. Typically, the well is left flowing and gas lift is increased to maximum in order
to maximize wellbore velocity. Starting maximum gas lift while running in the hole allows the
system to stabilize before reaching bottom. While RIH, it is also a good time to displace
MeOH from the coil at minimum rate so as not to damage the motor stator
In wells with low bottom hole flowing pressures, the hydrostatic head of the methanol or
water in the coiled tubing may considerably exceed the flowing pressure outside the coil
while running in the hole. If this occurs, the motor could start spinning and open the
underreamer blades. It is then difficult to get through mandrels and the tailpipe. To minimize
this chance, go in the hole slower to allow the normal fluid bypass around the motor bearings
to keep up with the coil capacity being run in the hole. With the DB underreamer you may
have to shut-in the well to get in the hole, as even flow upward passed the bit area may open
the blades. Note that the motor spinning while running in hole with a mill is not a problem.
3) Prior to tagging total depth, reduce pump rate to minimum, or stop it completely and dry tag
the top of the fill (or fish). This tag depth is recorded and compared to the wireline gauge run
depth or other operation that determined the required cleanout.
4) When opening the underreamer, do so in an area where the arms will not be constrained if
possible. If inadvertently you underream to bottom without the blades fully open, a pilot hole
will be drilled instead of a full gauge hole. If clean pipe is available, then after tagging TD
with the underreamer or mill, pull back to a point where there is no restriction, and begin
pumping. If everything is functioning properly, increase the pump rate to the motor’s
optimum. Note the free spinning pressure and pump rate at this point.
5) If opening the underreamer in on constrained hole, such as when scale is all way up to the
tubing tail, then a different procedure is required. Starting below the tubing tail, autodrill
slowly in the hole such that you are attempting to mill and open the blades at full pump rate.
With the Weatherford (Reeves) underreamer, after autodrilling two-three feet down, pick the
pipe back up and repeat. Because there are no definitive indications at surface whether or
not the underreamer is fully open, it is recommend to spend a half an hour with perhaps six
cycles over the same two-three foot interval before proceeding to underream the rest of the
liner.
With the DB, the above applies however the two-three foot section can be reamed in both up
and down directions.
Calipers run after underreamers have shown that if this initial cut is not properly made, entire
sections of the liner are severely undergauge.
6) Once the two-three ft opening is made, continue RIH. When the restriction is encountered,
take a little time to allow the underreamer/mill to establish its cutting pattern. This is done by
applying weight to the tool very slowly and allowing the tool to drill off. After making 1 to 2
feet in this manner, 500 lbs can be placed on the tool while observing pressure to detect a
stall. Once the pump pressure stabilizes and no stall occurs, the weight can be increased to
700 to 800 lbs, again allowing the parameters to stabilize. Once this occurs the weight can
be even further increased to 1000 lbs. Observe the pressure very carefully during this period.

Note: The suggested weights are for a 2-7/8” motor. Check optimum pressure, pump rate
and allowable weight for other motors with the service company representative.
If the DB underreamer arms encounters a hard obstruction even with the arms fully
extended, it may or may not stall the motor or result in set down weight; with funnel-shaped
hard scale the arms may simply collapse in with no discernible indications at surface. The
Weatherford (Reeves) underreamer blades expand into more of a flat downward face profile
and are unlikely to collapse back in if they have been kept fully extended in clean pipe.
Instead, a stall or set-down is more likely to be experienced when any type of hard
obstruction is encountered and the ROP is greater than the ability to grind away it away.
The penetration rate is normally a function of the weight on bit, the hardness of the material,
and the ability to clean the hole. Typical under-reaming rates in cement from recent
squeezes are 15 to 30 feet per hour (fph), but can vary significantly depending upon
hardness and whether aggregate or fiber was used in the cement. Cement which has been in
place for several months can drill as slow as 2 to 3 fph. Calcium carbonate scale can usually
be reamed at 30 to 50 fph, but some harder sections may slow down to 1 to 2 fph. The
maximum speed should be constrained to 50 fph, especially with the DB underreamer
because the arms may be pushed back in if funnel shaped scale is encountered.
Be aware that fast milling of either cement or scale causes larger cuttings and cuttings
volumes, poorer hole cleaning, and can lead to stuck pipe. Be happy with 50 fph! This is
especially an issue with barium sulphate milling (found at Pt MacIntyre field). Barium
sulphate scale can be deceptive: there have been cases with soft scale where we did not
think we were milling scale at all. We penetrated too fast, and stuck the pipe. Therefore, the
maximum penetration rate while turning the motor should be 50 fph in 5-1/2” pipe; this
maximum ROP can be adjusted up or down for other pipe sizes using the same volumetric
hourly equivalent. Even if it feels like you have broken through a bridge and there is no scale
below, you should only continue deeper at the 50 fph rule. The alternative to this is to short
trip to the gas lift point (if running a mill) or to the tubing tail (if running an underreamer) and
clear the entire hole of cuttings, then perform a dry tag. This carries with it some risk so
carefully consider the need for this versus just carrying on as if scale is indeed present.
The following case history data for barium sulphate scale from the Miller field (North Sea)
and is provided to illustrate the point of milling too fast. The
Particle Size Distribution
Scale Particle Size 2 FPM ROP 0.75 FPM ROP
Larger than 2.8 mm 2% <.5%

1.7- 2.8 mm 8% <.4%
1.0- 1.7 mm 19% 1%
500 um- 1 mm 31 % 5%
250- 500 um 21 % 30%
125- 250 um 17 % 40%
Smaller than 125 2% 22%
um

The weight on bottom is another important parameter. Typically 500 to 1000 lbs is
maintained when drilling cement or scale. If the tools stall frequently, it may be necessary to
apply less weight, 100 to 200 lbs, for short intervals. In highly deviated holes, it can be hard
to determine actual weight on bottom from the weight indicator. The coil operator must
maintain constant pump pressure rather than weight on bottom in this situation. Since stalls
produce the worst stresses on the BHA and coil, it is better to drill with less weight and fewer
stalls than push the weight which generally increases the stalls dramatically.
Stalls reduce the motor life and the average rate of penetration. A stall is indicated by a rapid
increase in pump pressure without increasing pump rate. The differential pressure across a
motor is a function of the RPM of the motor. Adding weight on bottom increases the bite of
the underreamer, reduces the motor speed, and increases the pump pressure. The increase
in pressure from normal operating speed to the point at which the motor completely stops is
called the incremental stall pressure.
The incremental stall pressure depends on the motor size and manufacturer but is typically
at least 600 psi. On account of variations in motors, discuss acceptable stall pressure with
the service company representative. To prevent the motor from completely stalling and
placing very high torque on the coil, a sudden pump pressure increase of 500 psi should be
considered a stall and the appropriate action taken.
6) When a stall occurs, stop pumping and allow the pressure to bleed off, ensuring the motor is
stopped.
Before re-starting the pump, pick up the underreamer/mill 10 to 30 feet off bottom. This
reduces the potential of backing off at a connection in the BHA by picking up off bottom with
the torque (from stall) stored in the bottom portion of the coil. Always keep the pipe
moving until the pumps are back online, as solids will be falling back in on the BHA.
Once the pump pressure is stable, run the underreamer/mill back to the depth of the
restriction. Never attempt to start the motor with the underreamer/mill touching bottom. Many
stuck pipe incidents occur either immediately after a stall, or after picking up and re-starting
milling operations. It is suspected that in the latter case this is as a result of cutting falling
down around the BHA. Therefore, if a substantial amount has been milled after stalling, then
take steps to clean the hole prior to resumption of milling new hole. Once resuming under-
reaming/milling, reduce the penetration to a minimum until reaming parameters are again
established.
Note: The suggested weights are for a 2-7/8” motor. Check optimum pressure, pump rate
and allowable weight for other motors with the service company representative.
8) The power fluid (slick water) is not efficient for lifting cuttings, so the following guidelines are
provided for pumping viscous sweeps to carry cuttings out the well;
a) for every one-two bbls of hole milled, pump a viscous sweep

b) sweep size should be a minimum of 10 bbls (in 4-1/2 or 5-1/2”) and 15- 20 barrels in 7”.
The deeper the well, the more the pill will string out on the way up the hole so consider
increasing these amounts by a few barrels below 10,000 ft
c) stage the gel to arrive when you have nearly milled the 1-2 bbls of hole volume interval.
Pick the pipe up and wash down through the just milled interval to entrain the cuttings in
gel
d) Do not shut down for dry tags until the previous sweep has reached the surface.
The pump pressure will increase while pumping the high viscosity sweep down the coil.
Pumping the water into the well will increase the average density of fluid in the wellbore; and
in many instances, move the entry point of the gas lift gas to a higher gas lift valve,
increasing bottom hole flowing pressure and reducing inflow from the formation, thus
reducing the fluid velocity. This may dictate how fast you can pump, or more likely, how long
of an interval you can underream/mill before allowing the water and cuttings to be removed
from the wellbore while pumping at minimum rate.
9) Make frequent short trips through high angle section, minimum every 250’. If possible, bring
these above the lifting GLV. This distance might be varied based on the particular hole
cleaning challenges.
10) Milling or under-reaming in one spot for very long can cause major casing or tubing wear. If
there is no progress, and there is not an obvious reason for the slow penetration rate, pull
the BHA to determine the problem. This is a judgment call based on the type of cutting
structure and rotating time.
11) If stalls are excessive, over 50, then consider changing BHA. Fatigue of the coiled tubing
near the
connector because of motor vibration and transmitted torque can cause the coil to twist off
above the fishing neck. Also, the underreamer blades can mushroom if run time is
excessive, preventing them from retracting back into the body of the tool. Keep circulation
rates constant and fluids consistent so that circulating pressures can be monitored closely for
signs of developing cracks or broken connections in the BHA.
12) When making a BHA change out, pump a viscous sweep down the coil. Once gel has
passed through and out the nozzle, chase the sweep out of the hole. Freeze protect the coil
when nearing surface if weather dictates. Cut off at least 30 feet of coiled tubing and install
a new BHA. Replace the underreamer blades or mill if it is worn and out of gauge.
13) Once the target total depth has been reached with the underreamer/mill, at least one
additional pass should made from just below the tubing tailpipe to the clean out depth at 30
to 50 fpm to ensure that all restrictions have been removed and to help lift solids off the low
side of the hole and circulate them into the tubing.
14) A final viscous sweep of at least 20 barrels should be pumped. If the circ sub is to be
opened, pump a bottoms up volume after the 20 bbl viscous sweep and then shut down
pumping and verify the blades will close by pulling into the tubing before dropping the ball.
Pump another viscous pill with the ball and when the circulating sub opens, increase the
pump rate to the maximum coil operating pressure to circulate out the polymer sweep at the
highest rate possible. If the milling was done with a high flow rate motor or if sticky spots
were encountered while RIH or PUH during the job, it may be better to not drop a circ ball
and chase the solids out at 80% with the mill turning. Be sure the BHA is below the viscous
sweep before chase water reaches the end of the coil to avoid dilution of the gel. Once the
sweep is into the tubing, pull the coil out of the hole at 80% of the annular velocity while
continuing to pump. Do not stop pumping until the BHA is at the surface. A final slug of
solids is often lifted with the coil despite the bottoms-up calculations. When switching to
methanol water for freeze protect, CT pumping rates decrease and it is important to slow CT
so that the final slug of solids is not outrun.
15) “Backreaming” is generally not a good idea with the Weatherford (Reeves) underreamer.
Your milling should be done in a forward direction preferably. Backreaming with the
Weatherford (Reeves) could result in mushroomed blades that will not retract into the body.
The DB is capable of cutting material in the backreaming mode.
Note: it is considered somewhat risky to run into the hole deeper after opening the circ sub
because the fluid is no longer exiting from the bottom of the BHA.
16) Once out of the hole, inspect the blades. With the Weatherford (Reeves) underreamer, you
should see wear on the blade faces and little wear on the blade backs. If the blade backs
are badly mushroomed, this indicates the underreamer was not fully opened so the interval
needs underreaming again with the blades fully open. With the DB underreamer, there are
fewer such positive signs. An indentation on the back of the blades where they stop on the
tool body indicates that the underreamer was fully open at least once. The downward-facing

blade cutting surface wear may not be a definitive indication that the underreamer was fully
open, since the underreamer blades can still be cutting without being fully open.
There are numerous under-reaming problems that are indicated with the surface gauges. The
following table is provided to help diagnose a problem.
A. 100 -500 psi loss

A.1 Bad gauge reading. A.1a) Check other gauges and change out if bad.
A.2 Entering perforated interval, lower A.2a) Check depths and flowrate if possible.
gradient fluid entering wellbore.
A.3 Different fluid or change in properties A.3a) Check fluid tallies and recent tank swaps, wait for
such a change in friction reducer mix. complete coil volume change.
A.4 Leak in hardline or reel at surface. A.4a) Check hardline and reel at surface for any signs
of leaks.
A.5 Possible: A.5a) Pick up off bottom, compare off bottom circulating
pressure with drilling differential pressure.
 Leak in coil down hole OR A.5b) Ease down with little or no detectable weight on
 Weak/washing out motor OR bit.
 BHA twisted off OR A.5c) Set weight down on bottom, attempt to stall motor.
 BHA backed off OR A.5d) Change fluid source.
A.5e) Pull out of hole to check tools.
 Wash out in tool string.
B. 500 -1500 psi loss

B.1 Bad gauge reading. B.1a) Check other gauges and change out if bad
B.2 Entering perforated interval, lower B.2a) Check depths and flowrate if possible.
gradient fluid entering wellbore.
B.3 Leak in hardline or reel at surface. B.3a) Check hardline and reel at surface for any signs
of leaks.
B.4e) Pull out of hole to check tools.
B.4 Possible: B.4a) Pick up off bottom, compare off bottom circulating
 Weak/washing out motor OR B.4b) Ease down with little or no detectable weight on
 BHA twisted off OR bit.
 BHA backed off OR B.4c) Set weight down on bottom, attempt to stall motor.
 Wash out in tool string. B.4d) Change fluid source.
B.4e) Pull out of hole to check tools.
C. 100 - 500 psi gain.

C.1 Milling normally. C.1a) Continue drilling and monitor.

C.2 Bad gauge reading C.2a) Check other gauges and change out if bad..
C.3 Different fluid or change in properties such C.3a) Check fluid tallies and recent tank swaps, wait
a change in friction reducer mix for complete coil volume change.
C.3b) Increase friction reducer.
C.4 Annulus full of cuttings or falling off wall C.4a) Make short trip up.
C.4b) Increase circulation rate if possible.
C.4c) Check return line for blockage.
C.4d) Sweep wellbore with gel
C.5 Annulus fluids increasing in density C.5a) Decrease rate of penetration.
C.5b) Let well flow by decreasing well head pressure.
C.5c) Increase artificial lift
C.6 Leak in hardline or reel at surface C.6a) Check hardline and reel at surface for any signs
of leaks which would prevent motor from
turning
C.7 Possible: C.7a) Pick up off bottom, compare off bottom
circulating pressure with drilling differential
 Motor plugged OR pressure.
 Tool string plugged OR C.7b) Ease down with little or no detectable weight on
 Leak in coil down hole. C.7c) Set weight down on bottom, attempt to stall
motor.
C.7d) Change fluid source.
C.7e) Pull out of hole to check tools.
D. 500 - 1500 psi gain.

D.1 Bad gauge reading D1.a) Check other gauges and change out if bad
D.2 Different fluid or change in properties D.2a) Check fluid tallies and recent tank swaps, wait for
such a change in friction reducer mix. complete coil volume change.
D.2b) Increase friction reducer.
D.3 Motor stalled or not turning D.3a) Shut down pumping and let pressure bleed off,
pick up and start pumping, monitor pressure.
D.3b) If pressure is still high, try stalling motor to ensure

it is rotating
D.4 Possible: D.4a) Pick up off bottom, compare off bottom circulating
 Motor plugged OR D.4b) Ease down with little or no detectable weight on
 Tool string plugged OR bit.
 Weak/washing out motor OR D.4c) Set weight down on bottom, attempt to stall
 Tubing kinked. motor.
D.4d) Change fluid source.
D.4e) Pull out of hole to check tools
E. High circulating pressure.

E.1 Bad gauge reading E.1a) Check other gauges and change out if bad
E.2 Annulus full of cuttings or falling off wall E.2a) Make short trip up.
E.2b) Increase circulation rate if possible.
E.2c) Check return line for blockage.
E.2d) Sweep wellbore with gel
E.3 Annulus fluids increasing in density E.3a) Decrease rate of penetration.
E.3b) Let well flow by decreasing well head pressure.
E.3c) Increase artificial lift
E.3d) Continue drilling operations with caution

E.4 Flow line choked not functioning properly E.4a) Circulate hole clean, shut down pumping, close
or is plugged surface choke and check to see if surface lines
bleed of rapidly or slowly.
E.4b) If slowly, the surface lines are plugged and need
to fix problem.
E.4c) If rapidly, continue drilling operations with caution.
E.5 Water not very slick 5.5a) Swap fluids or add additional J313 to water.
F. Positive coil pressure when not pumping.

F.1 Bad gauge reading F1a) Check other gauges and change out if bad
F.2 Motor stalled or not turning F.2a) Shut down pumping and let pressure bleed off,
F.2b) Try stalling motor to ensure it is rotating.
F.3 Check valve not holding F.3a) Continue drilling operations with caution
F.4 Pressure held by torque or motor F.4a) Work tool string up and down, being careful not to
(stator/rotor clearance). set too much down (3k to 5k) or pull up to (5k to
10k) above string weight.
F.4b) Pull out of hole to check tools
G. Motor will not stall.

G.1 Little or no material to drill G.1a) Continue drilling operations with caution
G.2 Motor stalled or not turning. G.2a) Shut down pumping and let pressure bleed off,
G.2b) Try stalling motor to ensure it is rotating
G.3 Leak in hardline or reel at surface G.3a) Check hardline and reel at surface for any signs
of leaks
G.4 Possible: G.4a) Pick up off bottom, compare off bottom circulating
 Leak in coil down hole OR G.4b) Ease down with little or no detectable weight on
 BHA twisted off OR G.4c) Set weight down on bottom, attempt to stall
 BHA backed off OR motor.
G.4d) Pull out of hole to check tools.
 Wash out in tool string OR
 Motor plugged OR
 Tool string plugged OR
 Tubing kinked.
H. Frequent and excess stalls on motor.

H.1 Leak in hardline or reel at surface H.1a) Check hardline and reel at surface for any signs
of leaks
H.2 Junk in hole, possible collapsed pipe or H.2a) Make short trip up.
washed out perfs H.2b) Increase circulation rate if possible.
H.2c) Sweep wellbore with gel.
H.2d) Continue drilling operations with caution
H.3 Possible: H.3a) Pick up off bottom, compare off bottom circulating
 Leak in coil down hole OR H.3b) Ease down with little or no detectable weight on
 BHA twisted off OR H.3c) Work tool string up and down, being careful not to
 BHA backed off OR set too much down (3k to 5k) or pull up to (5k to
 Wash out in tool string OR
H.3d) Pull out of hole to check tools.
 Motor plugged.
I. Unable to pass through jewelry or tailpipe.

I.1 Hydraulically locked I.1a) Shut down pumping and run in hole.
I.1b) If well is flowing, shut in and run in hole
I.2 Junk in hole, possible collapsed pipe or I.2a) Shut down pumping and run in hole at varying
washed out perfs speeds.
I.2b) Pick up hole 200’ and run in hole.
I.2c) Set 2-3K weight down.
I.2d) Increase pump rate and run hole or set weight
down
I.3 Tight OD & ID tolerances and wellbore I.3a) Pull out of hole to check tools.
configuration. I.3b) Add straight pipe or reconfigure BHA.
I.4 Underreamer blades not in the closed I.4a) Pick up, change pump rate and RIH (or POOH)
position. I.4b) Pull out of hole to check tools.
J. Stuck or unable to pick up.

J.1 Annulus full of cuttings or falling from wall. J.1a) Do not shut down pumping.
J.1b) Make sure sufficient fluids on location and
continuous source of delivery.
J.1c) Do not try reversing.
J.1d) Work tool string up and down, being careful not to
set too much down (3k to 5k) or pull up to (5k to
J.1e) Estimate stuck point using free point calculation.
J.1f) Minimize cycles and reduce coil pressures when
pulling.
J.1g) Sweep wellbore with gel and condition hole.
J.1h) Increase circulation rate if possible.
J.1i) Increase friction reducer.
J.1j) Check return line for blockage.
J.1k) Let well flow by decreasing well head pressure.
J.1l) Shut well head pressure and let pressure build up,
then dump rapidly to “shock” free the solids.
J.1m) Increase artificial lift or use Nitrogen.
J.1n) Pump weak acid through BHA
J.2 Mechanically stuck. J.2a) Pump ball to open hydraulic disconnect.

J.2b) Chemically cut coiled tubing with e-line.
8.0 Risk Analysis

The following tables list the risks that would be typically encountered on a milling or under-
reaming job using coiled tubing. The hazards shown in the following tables are in addition to
those shown in the tables in the Risk Analysis for Coiled Tubing Operations document, which
address the hazards common to all North Slope coiled tubing jobs. The risk analysis should be
reviewed prior to starting a milling / under-reaming job. If additional risks for a specific job are
identified, the impact should be assessed and remedies/mitigating measures should be
discussed and documented.
Each hazard identifies the potential impact to personnel, the environment and economics. The
probability of an incident happening and the frequency of an incident happening is rated as very
low, low, medium, high or very high. For example, for the hazard of exposure to cold, the

potential for personnel contracting frostbite is low and the impact to an individual if they were
frostbitten is low.

Milling / Under-reaming with Coiled Tubing

Risk Assessment Table
Potential for Injury / Probability of Risk Occurring /

Description of Risk / Hazard Environmental Harm / Impact of Hazard (Very Low to Remedy / Mitigation
Economic Loss Very High)
Wind speeds > 20 mph – impact rig up and Personnel – injury Very Low Occurrence – Low 1. Discuss at safety meeting
rig down operations. Additional impact impact 2. DO NOT rig up or rig down
because of longer lubricator to handle BHA in unsafe conditions. Wind
Equipment – damage Low Occurrence – Medium speed > 35 mph or wind
impact speed > 25 mph when
direction is across the CTU
Environment - spills Very Low Occurrence – Low 3. Variance required for VMS
impact crane operations
Stuck Coil – may require cutting coil and Personnel – injury Low occurrence – High impact 1. Monitor returns and
increased potential for parting pipe pressures
Low occurrence – Medium 2. Use frequent viscous gel
Environmental – spill, impact sweeps and short trips.
possibly major if loss of well 3. Be patient
control;
Medium Occurrence – Low
Environmental - gas release impact
if flowing to tanks
Economic – damage to Very low Occurrence – High

equipment and facilities; impact
additional workover cost; loss
of well; loss of production
Live fluid going to tanks Personnel – injury Very Low Occurrence – Low 1. Discuss in safety meeting
impact 2. Increases potential for fire
or explosion
Environmental – spill; Low Occurrence – Low impact 3. Consider using mobile
separator to monitor returns
Medium Occurrence – Low and minimize hydrocarbons
Environmental – gas release impact to flowback tanks.
4. All flowback tanks in
secondary containment
5. DO NOT take returns to
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Potential for Injury / Probability of Risk Occurring /

Description of Risk / Hazard Environmental Harm / Impact of Hazard (Very Low to Remedy / Mitigation
Economic Loss Very High)
open top tank if high GOR
6. DO NOT take returns to
tanks if H2S present in
returns
Fluid contamination – biozan and/or Environmental – Low Occurrence – Medium 1. Do not swap fluids ‘on the
methanol; methanol and Flo-Pro contaminated fluid can impact fly’. Disconnect methanol
become a disposal problem hose before pumping
biozan – and vice versa
Economic – Tie up vac truck 2. Do not allow Flo-pro and
or tank with contaminated Low Occurrence – Low impact methanol to mix – forms
fluid thick gel / emulsion which
cannot be pumped and is
difficult to break
Lose fish in well – higher potential if using Personnel – injury Low Occurrence – Low Impact 1. Monitor pressures closely.
an underreamer in large casing with small 2. DO NOT put too much
tubing If going to system: Low weight on bit / BHA
Environmental – spill Occurrence – Low impact 3. Make frequent sweeps with
biozan or Flo-Pro
If going to tanks: Medium 4. Do not run motor for more
Occurrence – Low Impact than 24 hrs without POOH
to check BHA
Low Occurrence – Medium
Economic – loss of well; lost Impact
production; additional
workover cost

PAPER COPIES ARE UNCONTROLLED. THIS COPY VALID ONLY AT THE TIME OF PRINTING. THE CONTROLLED VERSION OF THIS DOCUMENT CAN BE FOUND AT
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Appendix 1: Technique to Increase Effective Weight on Bit

Workover projects on wells that have been recompleted with a coiled tubing sidetrack are
becoming more common. These recompletions typically are high angle or horizontal wells that
have been completed with a 2-7/8” liner (and in some cases with a 2-3/8” liner) below 4-1/2” or 5-
1/2” tubing. In addition to the high angles, these wells often have severe doglegs. For workovers
requiring the use of coiled tubing and a motor with a mill (or an underreamer), often the biggest
challenge is getting weight to the bit. Experience on several jobs has shown that by introducing
Lube-tex into the system, a dramatic improvement in transferring weight to the bit was achieved.
Lube-tex is a metal to metal friction reducer available from MI. The use of Lube-tex is
recommended only after attempting to mill using slick water. If weight cannot be consistently
applied to the bit, consider using the following set-up and Lube-tex.
Procedure:
The most effective and efficient way to utilize Lube-tex is to implement a re-circulation system.
There are several different set-ups that could be used but the recommended set-up is described
below:
1. Rig up a reverse skid with a return line going through a choke manifold to an open top tank
(re-circulation tank). The tank needs to have a weir to allow solids to settle out. Have the
return line discharge into the bottom of 1/3 of the tank upstream of the weir.
2. Rig up a hot oil truck so that the hot oil truck suction is from the return tank (downstream of
the weir) and the discharge is to the CTU pump.
3. Have a vac truck pick up 250 – 300 bbl of 120-130F, double slick, 2% KCl
4. Add 1 drum of Lube-tex to the KCl (1.4 – 1.7% by volume) and agitate on the way to the
location. MI recommends 1-3% by volume of Lube-tex. One drum per truck has worked well
in the past.
5. Pump the water with Lube-tex through the coil. Resume milling and take returns to the re-
circulation tank.
6. Continue the milling operation by using the slick water + Lube-tex.
Notes:
a.) Do not let the fluid volume in the re-circulation tank get too high. The fluid needs to be just
slightly above the weir to allow solids to settle out.
b.) When circulated fluids begin to show signs of high solids content, divert fluids returned to the
recirculation tank to a predetermined “dirty” return tank, continue this until the recirculation
tank is nearly empty. At that point swap to an upright tank and start inducing new clean fluids
to the system. Continue this process until a calculated volume of clean fluids is to surface. At
that point divert returned clean fluids back to the recirculation tank until fluids are slightly
above the weir in the tank continue with the recirculation process and have old fluids hauled
away. Repeat this when necessary.
c.) A hot oil truck is required to keep the water temperature above 85 F (110 - 120F is good) so
that the friction reducer for the water (J313) is effective.
d.) If circulating pressure increases, additional J313 may need to be added.
e.) A mobile test separator will be required if there are live or energized fluids. Defoamer may
also be required in this case.
f.) All tanks need to be inside secondary containment.

9.0 Key Documents/Tools/References

 BP Alaska PE Manual
 BP Operating Management System (OMS)
 BP’s Eight Golden Rules of Safety
 BP Global Drilling and Well Operations Practice
 Alaska Safety Handbook
 North Slope Environmental Field Handbook
 BP Alaska PE Manual
10.0 Lessons Learned

10.1 TeamLink LL # 10214 October 2008.
 When milling operations are planned with a venturi barrel/burnover shoe below the motor,
ensure venturi nozzles are sized to allow optimum maximum pump rate thru the motor.
10.2 TeamLink LL # 10448 March 17th, 2009

 The use of a coiled tubing unit was employed to mill 6000+ of barium scale. Consider
deploying Generation 2 buttons in the bit as opposed to generation 1 buttons. The Gen 1
buttons had a rake angle (taper on the backside), while these are more aggressive, they also
chip off quicker and wear down in less time. With Generation 2 buttons, achieve more
progress in less time, overall, with the more conservative design because the mill won't wear
out as fast. Currently there are a number of Gen 1 bits still out there and rather than pay a
redress charge, run the remaining ones as is and then redress with Gen 2 buttons.

Revision Log
Revision Date Approving Custodian/Aut Revision Details
Authority hor
Steve Rossberg Andrew Pfaff Original Issue
January 22, 2002
January 19, 2005 Doug Cismoski Judy Golding Updated to reflect current
organization structure
March 30, 2006 Jerry L. Bixby Wells Revised Approving Authority and
Operation Custodian. Extended next
Supervisor review date. Changed SOP to
RP.
March 23, 2008 Clark Olsen Charlie Special precautions on milling
Michel/Kevin too fast, and with sulphate scale
Yeager
October 16, 2008 Clark Olsen M. Seward / C. Added Section 10.0 - Lessons
Tzvetcoff Learned Added :LL #10214
April 13, 2009 Clark Olsen M. Seward / C. In Section 10.0 - Added LL
Tzvetcoff #10448
May 28, 2010 Tyler Norene / Clark Kevin Yeager Updated with minor changes.
Olsen Document reviewed for technical
accuracy.
July 22, 2010 Andy Kirk Chris Tzvetcoff Add BP Confidentiality
Statement
(or, see attached e-mail )

Approving Authority signature Date


Under-Reaming & Milling With CT

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Recommended Practice: Under-reaming and Milling Page 1 of 20

Alaska Wells Group

AK, D&C Well Services AK, D&C Wells CT

INTELLECTUAL PROPERTY AND CONFIDENTIALITY NOTICE

Note: Section 10.0 contains Lessons Learned from the field.

3.0 General Requirements

4.0 Key Responsibilities

Well Site Leaders are:

BP Confidential and © 2009 BP America Inc.

5.2 Special risk factors

5.3 Tool Descriptions

BP Confidential and © 2009 BP America Inc.

BP Confidential and © 2009 BP America Inc.

 For 2-3/8” liner, a 1.69” OD motor is the only choice.

5.3.4 Motor Head Assembly

- Coiled tubing connector

BP Confidential and © 2009 BP America Inc.

BP Confidential and © 2009 BP America Inc.

6.1 Recommended Equipment

6.1.1 Milling with returns to the system:

6.1.2 Milling with returns to tanks:

BP Confidential and © 2009 BP America Inc.

BP Confidential and © 2009 BP America Inc.

Particle Size Distribution

Scale Particle Size 2 FPM ROP 0.75 FPM ROP

Larger than 2.8 mm 2% <.5%

BP Confidential and © 2009 BP America Inc.

a) for every one-two bbls of hole milled, pump a viscous sweep

BP Confidential and © 2009 BP America Inc.

A. 100 -500 psi loss

B. 500 -1500 psi loss

C. 100 - 500 psi gain.

C.1 Milling normally. C.1a) Continue drilling and monitor.

D. 500 - 1500 psi gain.

D.3b) If pressure is still high, try stalling motor to ensure

E. High circulating pressure.

E.3d) Continue drilling operations with caution

F. Positive coil pressure when not pumping.

G. Motor will not stall.

H. Frequent and excess stalls on motor.

I. Unable to pass through jewelry or tailpipe.

J. Stuck or unable to pick up.

J.2 Mechanically stuck. J.2a) Pump ball to open hydraulic disconnect.

8.0 Risk Analysis

BP Confidential and © 2009 BP America Inc.

BP Confidential and © 2009 BP America Inc.

Milling / Under-reaming with Coiled Tubing

Potential for Injury / Probability of Risk Occurring /

Economic – damage to Very low Occurrence – High

Potential for Injury / Probability of Risk Occurring /

BP Confidential and © 2009 BP America Inc.

Appendix 1: Technique to Increase Effective Weight on Bit

BP Confidential and © 2009 BP America Inc.

9.0 Key Documents/Tools/References

10.0 Lessons Learned

10.2 TeamLink LL # 10448 March 17th, 2009

BP Confidential and © 2009 BP America Inc.

(or, see attached e-mail )

BP Confidential and © 2009 BP America Inc.

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