Casing Window Milling With Abrasive Fluid Jet

Abstract

Abstract Methods for through tubing re-entry drilling of multilateral wells has a large potential for increasing hydrocarbon production and total recovery. One of the bottle-necks of this technology is initiation of the side-track by milling a window in the casing downhole. A new approach to this problem has been investigated in a joint industry project. An experimental set-up has been built for milling a 4" window in a 7" steel casing at surface in the laboratory. A specially designed bit developed at RF using abrasive jet cutting technology has been used for the window milling. The bit has an abrasive jet beam which is always directed in the desired side-track direction, even if the bit is rotating uniformly. The bit performs the milling with a combined mechanical and hydraulic jet action. The method has been successfully demonstrated. The experiments has shown that the window milling can be performed with very low WOB and torque, and that only small side forces are required to perform the operation. Casing milling has been performed without a whipstock, a cement plug has been the only support for the tool. The tests indicate that milling operations can be performed more efficiently with less time and costs than what is required with conventional techniques. However, the method still needs some development of the downhole motor for coiled tubing applications. The method can be used both for milling and drilling giving the advantage of improved rate of penetration, improved bit life and increased horizontal reach. The method is planned to be demonstrated downhole in the near future.