United States Patent McGarian et al. (a) WHI TOCK CASING MI ING SYSTEM. (75) Inventors: Bruce MeGarian, Aberdeen (GB); Charles H. Dewey, Houston, TX (US) (73) Assignee: Smith International Ine., Houston, TX (vs) (2). Notice: Subject to any dislaimer, the term of this patent is extended or adjusted under 35 USC. 154(b) by 0 days, 09/937,399 Mar. 24, 2000 (21) Appl. No. 2). PCT Fle (86) PCTNo: —— PCT/GBOWOLI62 §371 OX), (©). (4) Date (87) PCT Pub, No. Nov. 28, 2001 woUH/s8s94 PCT Pub, Date: Oct. 5, 2000 (30) Foreign Application Priority Data E2IB 200, E210 7108 166/117.6; 166/50; 166/35.75 166/297; 175/61; 175/81 Mar. 26,1999 (GB) imc? us. Fleld of Search 166,313, 50, 1175, 166/117.6, 297, 58, 35.7; 175/61, 62, 320, 79,81, 82 60) References Cited US. PATENT DOCUMENTS. 308,759 A 9/1075 Cagle 1691176 Sss1509 A SS0S247 A 971996 Hradick 11997 Brad Ls 0068806311 US 6,880,631 BL Apr. 19, 2005 (10) Patent No. 5) Date of Patent 53120349 A * 21958 Peasants 1667298 S767978 A 81908 Cant ta. Se16324 A + 1908 Sweaingen eta... A6O1ITS Sans) A MNI998 Lee eta, 16/1175 SSSLSUS A 31999 Renbock ot {6 1175 SSO4889 A * 1999 Dewey ot 1667298 FOREIGN PATENT DOCUMENTS cn 2am = ier ce Dass ier (OTHER PUBLICATIONS International Publ. No. WO 98/04804, by Mark H. Lee etal. ‘Apparatus and Method for Milling 8 Hole in A Casing. Primary Exaniner—David Bagnell Assistant Examinerdennifer Gay (74) Attorney, Agent, or Firm—Dykema Gossett PLLC 6 ABSTRACT This invention relates toa whipstock casing milling system and, more particularly, to such a system in which a window mills secured to a whipstock so thatthe system may be run into a well, set and operated to open a window in casing uring a single trip. The milling system of the present invention comprises a protrusion (B) provided on the whip- face of the whipstock whetcin the protrusion (B) forms an extension of a relatively steep ramp surface (48) of the ‘whipface so as to reduce damage to said surface (48) at @ juncture (A) of said surface (48) with a relatively shallow ramp surface of parallel surfce (46) during use of the system. The proinision (B) thereby avoids an undercutting ff a easing and a thinning of the whipstock. 7 Claims, 2 Drawing SheetsU.S. Patent Apr. 19, 2005 Sheet 1 of 2 US 6,880,631 B1 ra le »(¢F LEE EE ? Zee Zamna Kh Seetorssy PRIOR ART PRIOR ARTU.S. Patent Apr. 19, 2005 Sheet 2 of 2 US 6,880,631 B1US 6,880,631 BL 1 WHIPSTOCK CASING MILLING SYSTEM This invention relates to 4 whipstock easing milling system, and more particularly to sich a system i which @ ‘window mills secured tothe whipstock so thatthe system may be run info a wel, set and operated to open a window in the easing in a single trp. ‘A one trip easing milling system as described above is ‘sown in our Betsh patent publication GB2312702A. Inthe ‘system deseribed in this patent specification, a window mill, |S secured by means of shear bolt to the end of the ‘whipstock. The window mill includes 4 tapered end the taper of which matches the ramp angle ofthe end portion of| the whipstock. This ramp angle i relatively steep (typically 15°) so that, atthe stat of easing milling, the window mill Js foreed rapidly into the easing inorder to foem an intial ‘opening "Whilst this system for effecting the intial break through ‘of the easing offers considerable advantages aver the prior the arrangement does have the disadvarlage tha the area ‘of contact between the tapered portion of the window mill, And the intial steep ramp surface onthe whipstock (Le. the hearing ara) decreases as the window mill begins to pen- fc the easing. Although the whipstock camp continies to apply a lateral force tothe window mill the eaction force on the whipstock becomes progressively concentrated on 8 ‘small egion of the ramp face. Eventhough the whipstock ramp may be hardened, the fact thatthe reaction force from the Window mills conccatrated on a relatively small area of the ramp tends to lead to wear of the ramp. This wear is Particularly noticeable atthe point where there is change ‘of whipstock angle atthe Bottom end of the intial steep ramp portion. Immediately before the casing milling tool begins to un down the relatively shallow angled (or parallel) portion of the whipstock below the steep ramp, the ‘entire reaction force applied by the window mill to the whipstock is concentrated in this small area, Even if the ‘whipstock is extensively hardened in this area, wear will, Inevitably occur. One result of this wear is that the window in the casing is not opencd up as quickly as might be ‘expected from te initial (pre-wear profile ofthe whipstock ‘One prior art system according to the preamble of the appended claims (disclosed under international publication umber WO 98/0804) provides a partial solution 10 this problem but does not necessarily allow prevention of unde- sirable ramp wear under given conditions ‘We have now devised a complete solution to the afores ‘mentioned problem “The present invention provides a whipstock casing mill- ing gystem and a method for using the system. The protrusion wil, in practice, be milled partially or s ‘completely away during the casing. milling operation, However, the exisience othe protrusion prevents the exces- sive damage to the relatively sleep ramp surface of the ‘whipface sich as has occurred inthe prot at. The prot sion may be of any suitable material for example steel of a stitable grade, Tdeally, the protrusion is provided on the relatively shallow ramp surface or paralel surface of the whipface Preferably, the protrusion is removably secured tothe Whip- face. The protrusion may be movably secured by means of atleast one threaded fastener. vis further preferable for the protrusion to comprise a surface which is ramped at the same angle relative to the longitudinal axis ofthe whipstack a the felatvely steep ramp surface. The ramped surface of the protrusion and the relatively steep ramp surface are ideally amped at an angle of 15° relative tothe longitudinal axis of the whipstoc. 2 The invention wil be beter understood from the fallow ing description of a preferred embodiment thereof given by ‘way of example only, reference being had to the socomps- ying drawings, wherein FIG. 1 cortesponds to FIG. 4 of the above mentioned GB2312702A; FIGS. 2, 3 and 4illustate the milling apparatus of FIG. 1 in use during a casing milling operation; FIG. 5 illustrates the improvement according to the present invention; and FIGS, 6, 7 aad 8 illustate the milling apparatus of FIG. 5 in use during a casing milling operation, “Turning firsly to FIG. 1, there is shown a poction of the easing milling system of GB2312702. Reference should be hha to the text of this patent publication for further deserip- tion of the illustrated system. For the present purposes: however, it is sufficient to note thatthe illustrated s¥stem ‘comprises a window mill 32 which is secured toa whipstock ‘44 by a shear bolt 39. The whipsiock has a whipface which includes a relatively steep starler surface 48 followed by vertical surface 46 (ie. a Surface parallel to the longitudinal axis of the easing). Tho relatively sleep starter surface 48 ‘meets the vertical surface 46 ata transition point A. Is use, aler the illustrated casing milling sysem has been run in hole, a packer or anchor secured to the bottom of the Wwhipsock is set and the window mill 32 is released by shearing the shear bolt 39. The dril string is then rotated and ‘weight applied tothe window mill 32, The window mill ruas up the relatively steep starter surface 45 on the whipstock and is thereby forced laterally into the easing on the side thereof opposite the whipstock. The casing i disintegrated and the window mill moves downwardly. twill be appreciated that immediatly before the wine ‘dow mill moves on tothe vertical section 46 oF the whiplace, the enti reaction force of the window mill onto the \whipface is taken by the portion of the starter surface 48 ‘immediately adjacent the juncture A. This results in wear af the whiptace at this point with the result that the window mill snot forced cleanly through the easing as intended in the original design, Indeed, wear of the steep starter surface 4S typically begins well hefore the window mill 32 progresses onto the vertical surface 46. Tis is lustrated in FIGS. 2,3 and 4 of the accompanying drawings. In FIG. 2, the window mill 32 is shown atthe foot of the seep starter surface 48 prior to ‘commencing cutting ofthe well casing. As the window mil 32 is pushed up the starter surface 4§, te bearing area (i. te acva of contact betsveca the window mill and the starter steface) reduces. The Taeral reaction force applied by the ‘well casing onto the window mill does not reduce however and indeed tends to increase with the depth of cut. The stress inthe starter surface 48 produced by the window mill 32 is function of the lateral reaction foree and the bearing area ‘The dependency is such that the sess inthe starter surface 445 increases both as the lateral reaction Force increases and fs the bearing area decreases, Accordingly, as the window rill 32 moves up the sarer surface 48, the stress in the Starter surface 48 will increase until a eitical level is attained, at whieh point the starter surface 48 will begin to isintegrate. The minimum bearing area Z. before disinte- aration of the starter surface 45 begins is shown in FIG. 3 ‘As the window mill 32 progresses up the starter surface 48 ‘s0'as to reduce the bearing area belaw the minimum value, disintegration of the whipstock begins and the angle of the slarier surface 48 i effectively reduced, An undercutting of the well casing results, Depending upon the operational circumstances (incliding, for example, the eelative hardnessUS 6,880,631 BL 7 ‘of the whipstock and the well easing), the angle ofthe starter ‘surface 43 can, in an extreme case be reduced to zero (see FIG. 4), Io this event window in the well easing will not be formed, Referring now FIG. §, the above outlined problem is solved by means of »protnision H which is provided on the ‘whiptace immediately below the lower end of the state surface 45. The protrusion 1 in ellet extends the starter surface 45 downwardly of the well. The effect of the protrusion is to provide exia support forthe reaction forces Imposed on the whipface by the window mill and thereby reduce or prevent the undesired wearing aay ofthe starter surface 45 itself. In practice, the protrusion will n general be milled away in uso by the window mill, However, the ‘existence of the protrision ensures that adequate lateral ‘movement of the Window mill achieved before the win- ‘dow mill starts traveling down the vertial surface 46. The protrusion canbe of any suitable material andl can be secured 1o the whipface by any convenient means, for example by means of sews (such as 40 shown in FIGS. $10 8), or by 2 ‘welding Use of a whipstock casing milling system according to the present invention is shown in FIGS. 6 7 and a of the accompanying drawings. In FIG. 6, the window mil 32 is ‘shown at the Toot of the steep starter surface 48 prior t0 ‘commencing cutting of the well casing. As the window mill, 32 is pushed up the starter surlace 48, the bearing area inivally remains constant due to the provision of the pro- teusion B. Its only as the window mill 32 is pushed bed the ‘extended start surface 45 (see FIG. 7) thatthe bearing area begin to reduce. This eduction in betring area contributes toa increase in the sess within the starter Surface 48 and the ‘extension provided by protrusion B. However, the protrr- sion B is sized so that starter surface 48 is sulficieatly ‘extended for altinment ofthe critical sress level to be ‘delayed until the required lateral displacement of he win- ‘dow mill 32 has ooctred, As intimated above, this required lateral displacement occurs when the window mill 32 (pecially the largest outer diameter of the window mill, 32) reaches the juncture between the vertical section 46 of the whipface and the (unexteneded) starter surface 45. The extension to the starter surface 48 provided by the protrusion I is sized so as to provide a contact area with the ‘window mill 32 substanally equal tothe minimum bearing area Z indicated in FIG. 3 assuming the protrusion B is of an identical material to that of the whipstock aad the forces ‘exerted by the window mill 32 having reached juncture A {ce FIG, 7) ate identical to those exerted by the window mill 32 located inthe ertical position shown in FIG. 3). A skilled person will be capable of caleulating the precise dimensions ofthe protrusion Bt ia view of known operating ‘Oace the window mill 32 has progressed up the starts surface 4S to the postion indicated in FIG. 7, the lateral Feaction fores exerted by the window mill 32 in euting into the wellbore side are borne solely by the protrusion B. The arrangement is such thatthe extical stress level isnot rill autained until the window mill 32 progresses to of beyond the position of FIG. 7, When the critical sees level is attained, the protrusion B is either partially or wholly (as shown in FIG, 8) milled away. The starter surface 48 and vertical section 46 of the whipface remain substantially undamaged and a window is opened as required. The ‘whipstock itself may be used in future operations with a replacement protrusion B. o 4 The present invention is ot limited to the specific ‘embodiment described above. Allemative arrangements und suitable materials will be apparent to a reader skilled in the ‘What is claimed is 1. A whipsiock casing milling system comprising: & whipstock having a whipface, the whipface comprising & first ramp surface and a second ramp surface or parallel surface meeting the frst ramp surface a juncture, the first ‘amp surface being relatively steep compared to the second amp surface, said surfaces being ramped or parallel relative to the longitudinal axis of the Whipstock such that te frst ramp surface is disposed ata greater angle 0 said longitu inal axis than the second ramp surface; a window mill secured to the whipstock adjacent the fist ramp surface and ‘operable in use to form an opening in a wellbore casing ‘whieh the whipstock easing milling system is located, mi ing blades ofthe window mill being directly engaged with and deflected by the first ramp surface laterally into the feising as the window mill is rotated and forced along the first ramp susface toward the second ramp or parallel sur face; and a protrusion provided on the whipface, the pro- trusion forming an extension ofthe first ramp surface of the ‘whipface and being dceetly engaged by said miling blades. 8 Suid milling blades travel along said first ramp surface ‘to sid extension sa a8 Ta duce damage to the fist ramp surface at the juneture of the frst ramp surface and the ‘Second ramp or parallel surface during use of the system, the first ramp surface and the extension together forming @ mil ‘deflecting slope: wherein the Tength ofthe extension being such that, in use, the surface arca of the milling blades: ieelly engaging suid fist ramp surface section of Said mill Seflecting slope reduces asa consequence of the mill mow- ing along and projecting beyood said first ramps surface section of said mill deflecting slope, an inrease in sires in Sad fest camp sueface section of said mill deflecting slope due to said reduction in surface area being maintainable below a level which would eause damage to sid ist ramp surface section of sil mill deflecting slope uni the mill bas ‘moved beyond the relatively steep firs ramp surface and is ‘0 longer in engagement therewith 2. A whipsiock casing mill system as claimed in claim 1, ‘wherein a level of stress in said slope which would cause {damage to said slope is attained when the mill moves beyond the first ramp surface and is no longer in engagement therewith, 3. A whipstock casing milling system as 1, wherein the protrusion is provided on the second ramp or parallel surface ofthe whipface 4A whipstock casing milling system as claimed in elsim 1, wherein the protmision is removably secured to the whipface. ‘A hipsiock casing milling system as claimed in lain 1, wherein the protnision is removably secured to the \whipface by at east one threaded fastener. ‘6. Awhipstock easing milling system as claimed in claim 1, wherein the protrusion comprises a surface whieh is ‘amped atthe same angle relative tothe longitudinal axis of the whipstock as the first ramp surface 7. A whipsiock easing milling system a claimed in elsim 6, winerein said ramped suface of the protrusion and the first ramp surface are ramped at an angle of 15° relative to the longitudinal axis of the whipsiock.