Note: Descriptions are shown in the official language in which they were submitted.
. . -" Il~felYllY .~Y~r
CA 02526376 2006-02-10
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WELLBORE JUNCTION ASSEMBLY
This is a divisional application of Canadian Patent
Application Serial No. 2,326,489 filed on April 1, 1999.
This invention relates to a well comprising a primary
wellbore and a secondary wellbore leading from said primary
wellbore wherein a juncture is formed therebetween, said
juncture lined with a tubular member extending from said
primary wellbore into said secondary wellbore. It should be
l0 understood that the expression "the invention" and the like
encompasses the subject matter of both the parent and the
divisional applications.
Prior to the present invention, a lateral or secondary
wellbore was bored in a formation from the main or primary
wellbore. The primary wellbore is usually cased and the
lateral well is lined with liner. The liner may be hung
using a liner hanger, from the cased primary wellbore. A
packer may also be set to seal the annulus between the
casing and the liner. To re-establish fluid flow through
the primary wellbore, a mill is simply run through the wall
of the liner to establish an opening into the primary
wellbore.
A problem has been observed that the mill often mills
the wrong part of the liner.
According to a first aspect, the invention provides a
mill for use in a well comprising a primary wellbore and a
secondary wellbore leading from said primary wellbore
wherein a juncture is formed therebetween, the juncture
being lined with a tubular member extending from said ,
primary wellbore into said secondary wellbore, characterised
in that the mill has a cutting portion at a lower end
thereof, said cutting portion extending further downwardly
at its outer diameter than at a point inside its outer
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diameter, so as to mill an opening in said tubular into said
primary wellbore.
According to a second aspect, the invention provides a
well comprising a primary wellbore and a secondary wellbore
leading from said primary wellbore wherein a juncture is
formed therebetween, said juncture lined with a tubular
member extending from said primary wellbore into said
secondary wellbore, and a mill as described above.
Preferably, a stabiliser is provided for stabilising the
l0 mill as it mills an opening in said tubular into said
primary wellbore. The stabiliser stabilises or guides the
mill for milling an opening between the tubular member and
said primary wellbore. The tubular member may be the top
section of a liner lining the secondary wellbore, or a
section of tubular linking the primary wellbore (cased or
uncased) with the secondary wellbore (cased or uncased).
The invention also provides a wellbore junction
comprising a preformed portion of a lateral wellbore, a
first tubular member having an aperture formed in a wall
thereof, a diversion member disposed within the first
tubular member, and a second tubular member coaxially
disposed within the first tubular member, wherein the first
tubular member, the second tubular member, and the diversion
member are insertable into a wellbore in a single run, at
least a portion of the second tubular member permanently
disposable within the preformed portion of the lateral
wellbore.
The invention also provides a method for creating a
junction assembly proximate a junction between a main
wellbore and a lateral branch bore comprising operatively
coupling a first tubular member to a second tubular member,
whereby the first tubular member is substantially coaxial
with the second tubular member, thereby forming an assembly
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which is insertable into a wellbore, the second tubular
member having an aperture formed in a wall thereof, and
having a diverter member for cooperating with the first
tubular member to guide at least a portion of the first
S tubular member through the aperture, preforming the junction
by forming at least a portion of the lateral branch bore
from the main wellbore, inserting the assembly within the
main wellbore in a single run, positioning the assembly
proximate the junction, guiding the first tubular member
through the aperture, and permanently disposing at least a
portion of the first tubular member in the lateral branch
bore.
The invention also provides a wellbore junction
comprising a preformed lateral wellbore extending from a
main wellbore, a tubular member having an aperture formed in
a wall thereof, a diversion member disposed within the
tubular member, and a lateral liner member coaxially
disposed within the tubular member, wherein the tubular
member, the lateral liner member, and the diversion member
form an assembly that is insertable into the main wellbore
in a single run, and the lateral liner member is permanently
disposable within the lateral wellbore.
The invention also provides a junction apparatus for
installation proximate the intersection of a first wellbore
and a lateral wellbore extending therefrom, comprising a
first tubular member having an aperture formed in a wall
thereof and a diversion member proximate the aperture, and a
second tubular member operatively connected to the first
tubular member, such that the first and second tubular
members are substantially coaxial, wherein the first tubular
member, the second tubular member, and~the diversion member
are insertable into a wellbore as an assembly, and wherein
at least a portion of the second tubular member is
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extendable through the aperture and permanently locatable at
an extended position within a preformed portion of the
lateral wellbore.
The invention also provides a method for forming a
wellbore junction structure proximate a junction between a
first wellbore and a preformed portion of a lateral wellbore
extending therefrom comprising operatively connecting a
first tubular member having an aperture in a wall thereof
and a diversion member proximate the aperture, and a second
l0 tubular member, thereby forming an assembly wherein the
first and second tubular members are substantially coaxial,
moving the assembly in the first wellbore to a location
proximate the junction, extending the second tubular member
through the aperture, and locating at least a portion of the
second tubular member in an extended position into the
preformed portion of the lateral wellbore, thereby forming a
wellbore junction structure.
The invention also provides a method for forming a
wellbore junction structure proximate a junction between a
first wellbore and a lateral wellbore extending therefrom
comprising operatively connecting a first tubular member
having an aperture in a wall thereof and a diversion member
proximate the aperture, and a second tubular member, thereby
forming an assembly wherein the first and second tubular
members are substantially coaxial, moving the assembly in
the first wellbore to a location proximate the junction,
extending the second tubular member through the aperture,
locating the second tubular member in an extended position
thereby forming a wellbore junction structure, and running a
drilling member through the second tubular member.
The invention also provides a wellbore junction
comprising a first tubular member having an aperture formed
in a wall thereof, a diversion member disposed within the
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first tubular member, and a second tubular member
substantially coaxially disposed within the first tubular
member, wherein the first tubular member, the second tubular
member, and the diversion member are insertable into a
wellbore in a single run, and wherein the second tubular
member is permanently disposable within a lateral wellbore.
The invention also provides a wellbore junction
comprising a first tubular member having an aperture formed
in a wall thereof, a diversion member disposed within the
first tubular member, and a second tubular member
substantially coaxially disposed within the first tubular
member, wherein the first tubular member, the second tubular
member, and the diversion member are insertable into a
wellbore in a single run, and wherein the second tubular
member is extendable into a lateral wellbore, at least a
portion of the lateral wellbore preformed prior to inserting
the first tubular member, second tubular member, and
diversion member into the wellbore.
The invention also provides a method for creating a
junction assembly proximate a junction between a main
wellbore and a lateral branch bore comprising operatively
coupling a first tubular member to a second tubular member,
thereby forming an assembly which is insertable into a
wellbore, wherein the first and second tubular member are
substantially coaxial, the second tubular member having an
aperture formed in a wall thereof, and having a diverter
member for Cooperating with the first tubular member to
guide at least a portion of the first tubular member through
the aperture, inserting the assembly within the main
wellbore in a single run, positioning the assembly proximate
the junction, guiding the first tubular member through the
aperture, and running a drilling member through the first
tubular member.
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The invention also provides a method for creating a
junction assembly proximate a junction between a main
wellbore and a lateral wellbore, comprising providing an
assembly having a first tubular member operatively connected
to a second tubular member, whereby the first tubular member
is substantially coaxial with the second tubular member, the
second tubular member having an aperture in a wall thereof,
inserting the assembly within the main wellbore in a single
run, positioning the assembly proximate the junction,
extending at least a portion of the first tubular member
into the lateral wellbore, and permanently disposing the
first tubular member within the lateral wellbore.
Preferably, said stabiliser is arranged on said
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tubular member.
Advantageously, said stabiliser comprises ribs
extending into said tubular member with channels arranged
therebetween. The ribs are provided with flow channels
therebetween to allow fluid such as mud to flow past. If
the fluid flows a.n a direction away from the mill, the
mud will be carrying swarf from the mill during the
Inl.lling operation. The channels may be straight or
spiralled.
Preferably, said stabiliser comprises ribs extending
outwardly from said tubular member. The ribs centralising
the tubular member in the primary wellbore (which may be
cased) .
Advantageously, said stabiliser is made from a
bearing material such as zinc alloy.
Preferably, said stabiliser is hardfaced. Or may be
provided with matrix milling material which may ream any
casing of too small a diameter for the passge diameter
required.
Advantageously, said stabiliser is integral with
said tubular member. Although, the stabiliser may
comprise a threaded top and a threaded bottom for
attachment to said tubular member.
Preferably, said tubular member comprises at least
two stabilisers.
Advantageously, said stabiliser is a tubular which
has a close tolerence, such that a mill on the end of a
tool string will have a close fit therewith_ Preferably,
said tolerence is within 0.4mm (fifteen thousandths of an
inch) .
Advantageously, said tubular member initially
attached to said mill such that said tubular member may
be lowered thereon.
Preferably, said tubular member is supported by a
liner hanger. A packer to seal the annulus between a
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cased primary wellbore and the tubular member may also be
provided, or a metal to metal seal may be provided.
Advantageously, said mill is provided with a
centring device such that said mill enters said tubular
Without hitting. the top thereof.
Preferably, the liner comprises drift tubulars.
Advantageously, the well further comprises a bent
sub connected to a lower end of .the tubular member.
The invention also provides a stabiliser of of the
well of the invention. ~,
The invention also provides a tubular member
provided with at least one of the invention.
The invention also provides a mill for use in the of
the invention, including a first mill with an angled
cutting portion on a lower end thereof for maintaining
desired mill position during milling of the liner.
Preferably; the mill has an angled cutting
portion comprises crushed carbide secured to the first
mill.
Advantageously, the angled cutting portion is a
concave shaped area at the lower end of the first mill.
Preferably, the at least one mill has a mill body
with a body diameter and a lower end cutting structure
extending outwardly from the mill body to a lower end
diameter, and the lower end diameter is greater than the
body diameter.
The invention also provides a system for milling an
opening in a tubular comprising at least one stabiliser
of the invention, the tubular member of the invention and
the mill of the invention.
The invention also provides a method for milling an
opening in a tubular in a well of the invention, the
method comprising the step of milling an opening in said
tubular member whilst being stabilised or guided by said
stabiliser.
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Certain special drift casing has a known interior
diameter within a close tolerance, e.g. within forty
thousandths of an inch. Also, the exterior diameter of
the stabilizing members) is, optionally and preferably,
sized within a close tolerance, e.g. fifteen thousandths
of an inch. The resulting close fit between stabilizing
members) and casing increases stiffness of the system
and enhances stability of the mill(s). In one aspect
special drift casing is used at such a length that it
includes within it the milling assembly and the area for
forming a Window.
One particular mill useful in such systems has a
generally cylindrical body with a flow bore therethrough
from a top end to a bottom end. One or more flow ports
extend laterally from the flow bore to the body's
exterior. The lower end of the mill has a plurality of
spaced-apart blades for milling the liner. In various
aspects there are two, four, six, eight, ten, or twelve
separate blades, although any suitable number is within
the scope of this invention. The blades may be dressed
with any suitable known matrix milling material and/or
inserts by any suitable known method and in any suitable
known pattern or array. In one particular aspect the
blades extend downwardly with flow paths therebetween and
an amount of crushed carbide is disposed within the mill
partially adjacent and partially above the blades with a
lower cone shape that facilitates maintenance of the mill
in a desired milling position.
Preferably, a system as described above (and in
detail below) is releasably secured to a liner and the
entire combination is run into a wellbore so that the
liner enters and lines a portion of a lateral wellbore.
Any suitable known diversion device, whipstock, diverter,
etc. may be located in the primary wellbore at a desired
location to direct the liner into the lateral wellbore.
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Following- correct emplacement of the liner, the mills)
is/are selectively released from the liner (e.g. by
shearing a shearable member, stud, or pin) and the liner
is milled to reestablish communication to the primary
wellbore. The mills) and interconnected apparatuses are
then removed from the wellbore. This operation can be
completed in a single trip of the system into the
wellbore.
Alternatively, mills and milling systems described
1.0 herein may be used for any wellbore milling operation,
a . g . , but not limited- to milling a window in a wellbore
tubular, milling a fish, a packer, a whipstock, or other
apparatus or structure in a wellbore. In other
embodiments any mill or mill system described herein may
be used in conjunction with a mill guide.
The present invention also discloses systems and
methods for shrouding a main bore/lateral liner interface
in areas in which formation may be exposed or
unsupported.
The present invention also discloses systems and
methods for installing a liner in a lateral wellbore, the
liner having a preformed window located so that, upon
desired emplacement of the liner, the preformed window is
located above a main wellbore from which the lateral
wellbore extends- In this way the preformed window, in
one aspect, is positioned over a diverter or whipstock
used to direct the liner into the lateral wellbore. Thus
a mill is insertable and movable to and through the
preformed window to mill through the diverter or
whipstock, re-establishing the main wellbore.
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For a better understanding of the present invention,
reference will now be made, by way of example, to the
accompanying drawings, in which:
Figure 1A shows a side view in cross-section of a
prior art primary wellbore extending down from an earth
surface into a formation;
Figure 1B shows a side view in cross-section of a
lateral wellbore extending from the wellbore of Figure
1A;
Figure 1C shows a side view in cross-section of an
apparatus in accordance with the present installed in the
primary wellbore and lateral wellbore of Figure 1B;
Figs. 1D to 1F are side views in cross-section of
the primary wellbore and lateral wellbore of Figure 1C
showing steps in a method of milling in accordance with
the present invention;
Figure 2A is a side view in cross-section of a
coupling-bushing used in the apparatus of the present
invention; Figure 2B is a side view in cross-section
along line 2B-2B of Figure 2A; Figure 2C shows the
coupling- bushing as in Figure 2B with tungsten carbide
ground smooth on exterior rib surfaces;
Figure 3A is a side view in cross-section of a the
apparatus as shown in Figure 1C; Figure 3B is a side
view in cross-section of a part of a second embodiment of
an apparatus in accordance with the present invention;
Figure 4A is a side view of a mill in accordance
with the present invention with undressed blades; Figure
4B is a bottom end view of the mill of Figure 4A; Figure
4C shows an enlargement of part of the mill as shown in
Figure 4B; Figure 4D is a view in cross-section along
line 4D-4D of Figure 4A; Figure 4E is a view in cross-
section of the lower end of the mill of Figure 4A;
Figure 4F shows an enlarged portion of the mill end shown
in Figure 4E; Figure 4G is a side view in cross-section
CA 02526376 2006-02-24
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of the mill of Figure 4A; Figs . 4H - 4I show side view
of details of the lower end of the mill of Figure 4A;
Figure 4J is a view in cross-section along line 4J-4J of
Figure 4A;
Figure 5A, 5B and 5C are side views in cross-section of
a lateral shroud system in accordance with the present
invention; .
Figure 6 is a side view in cross-section of a
' lateral shroud system in accordance with the present
invention;
Figure 7 is a front view of a lateral shroud system
in accordance with the present invention;
Figure 8 shows schematically a side view in cross
section steps of a method of milling in accordance witla
the present invention;
Figure 9 is a side view in cross-section along line
9-9 of Figure 8 of an opening made with the mill of
Figure 8;
Figure 10 is a side view of a mill according to the
present invention;
Figure 11 is ~ a side view of a mill according to the
present invention;
Figure 12 is a side view of .a blade with a taper
member in accordance with the present invention;
Figure 13 is a side view of a blade with a taper
member in accordance to the present invention;
Figure 14A is a bottom view of a mill body
accordance with the present invention;
Figure 14B is a bottom view of a mill body
accordance with the present invention;
Figure 15A - 15D are side cross-section views of
mills accordance with the present invention;
Figure 16A, 16B, and 16E are side cross-section
views of a liner system according to the present
invention. -Figure 16C shows cross-section views along
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the length of the system as illustrated in Figure 16B.
Figure 16D is a cross-section view along line 16D-16D of
Figure 16B. Figure 16E shows a sleeve .of the system of
Figure 16A installed in a wellbore.
5 Figure 17 is a side view partially in cross-section
of a mill system according to the present invention.
Figure 18A is a side view in cross-section of a
generally cylindrical mill according to the present
invention . Figure 18B is a bottom end view of the mill
10 of Figure 18A.
Figure 19 .is a composite side cross-section view of
steps in an operation using a system as in Figure 17.
Figs. 19A - 19E are enlarged portions of Figure 19.
Figure 20 is a side view in cross-section that presents
15 an alternative embodiment of the system of Figure 17.
Referring now to Figure IA, a main wellbore W
extends down into an earth formation F and is cased with
a string of casing C. Such wellbores and the drilling of
them are old and well-known, as are the systems,
20 tubulars, and methods for casing them.
Figure 1B shows the results of well-known window
milling methods that have created a window D and well-
known drilling methods that have produced a lateral bore
L.
25 Figure 1C shows a liner assembly 10 according to the
present invention installed in part of the main wellbore
W and part extending into the lateral bore L. It is
within the scope of this invention for the part of the
liner assembly 10 to extend to any desired length into
30 the lateral base L, including substantially all of the
length of the lateral bore L.
A suitable support 12 holds the liner assembly 10
in place . In one aspect, the support 12 is an external
casing packer, but it is within the scope of t his
35 invention for it to be a liner hanger, tubing hanger,
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pack off or any support that supports ahe liner assembly
10. In another aspect, a non-sealing support or supports
may be used if no sealing between the exterior of the
liner assembly f0 and the casing interior is desired.
A tubular liner 14 :may be made from any suitable
material such as metal (steel, aluminum, zinc, alloys
thereof), composite, fiberglass, or plastic. Preferably,
the tubular liner 14 is bendable sufficiently for a lower
portion 16 to bend and enter into the lateral bore L. In
one aspect a bent tubular or bent sub 18 is connected at
the end of the lower portion 16 of tubular liner 14 to
facilitate initial entry of the tubular liner 14 into the
lateral bore L. Optional seals 13 seal the annular space
between a casing 38 and tubular members 14. Optionally,
an orienting apparatus 20 (including but not limiaed to a
measurement-while-drilling device) may be used connected
to the tubular liner 14 for correcting positioning and
orienting of the bent sub 18 and of the tubular liner 14.
Figs. 1D - 1F illustrate use of a milling system 30 to
re-establish a pathway through the main wellbore W after
installation of the liner assembly 10 as shown in Figure
1C. The milling assembly 30 has a mill 32 connected to a
tubular string 34 (e. g. a string of drill pipe, spiral
drill collars that facilitate fluid circulation, or
tubing) that extends to and is rotatable from the earth
surface. The wellbore W is cased with casing 38. The
tubular string 34 extends movably through one or more
(two shown) coupling bushings 36 (which connect together
tubulars 14) (see also Figure 3B). In one aspect a
spiral grooved drill collar which facilitates fluid
circulation and milled cuttings removal is used between
the bushings and/or thereabove; in one aspect, for thirty
feet above the mill. Alternatively, a third coupling
bushing' and/or a fourth may be used between the two
coupling bushings shown in Figs. 1D and 3B. Optionally,
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a liner hanger may be connected on the top of the top
coupling bushing shown in Figure 3B (in one aspect
interconnected via a.pup joint) to hold the tubular 14.
The milling system 30 and the tubular string 34 are
5 movable through the tubular liner 14 and through the
coupling bushings 36 so that longitudinal (up/down)
movement of the milling system 30 is possible. The
milling system 30 is also rotated as the tubular string
is lowered so that the mill 32 contacts and begins to
10 mill at an interior location on the tubular liner 14. In
one aspect the mill 32 simply makes a ledge (in a single
trip, preferably) (as in Figure 1E) in the tubular liner
34 that serves as a starting point for additional milling,
by another mill ~or mill system (not shown) that is
15 introduced into the main wellbore W following retrieval
of the milling system 30. As shown in Figure 1F, the
milling system 30 may be used to mill through the tubular
liner 34, re-establishing the main wellbore W and/or
creating a pilot hole which provides the location for
20 further milling by another mill or mill system.
Figs. 2A - 2C show a coupling bushing 40 usable as a
coupling bushing 36 in the milling system' 30. The
coupling bushing 40 has internally threaded ends 41 and
42 and a series of exterior ribs 43 between which fluid
25 can flow past the exterior of the coupling bushing 40. A
series of internal slots 44 provide an internal fluid
flow path through the coupling bushing 40. As desired
hardfacing or tungsten carbide material 45 may be applied
to outer surfaces of the ribs 43.
30 Figs. 4A - 4J illustrate a mill 50 usable as the
mill 32 of the milling system 30. The mill 50 has a body
51 with milling matrix material 52 (and/or blades with
milling inserts, not shown) applied spirally to the body
51 by known techniques. The material 52 may rough (e. g.
35 as applied) a ground smooth. As shown in Figure 4G, a
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fluid flow bore 53 extends from a top 54 of the body 51
to a bottom 55 where it communicates with an exit port 56
through the bottom 55 of the body 51. Alternatively,
additional exit ports may be provided. In one aspect the
inserts project beyond.milling matrix material.
The lower end of the mill 50 has a ribbed member 57
with a series of downwardly projecting lower portions 58
alternating with and spaced apart from a series of blades
59. Matrix milling material 60 is placed between the
blades 59 (covering mid portions 64) and over a lower end
61 of the body 51. In-one aspect, as shown in Figure 4E,
the matrix milling material is deposited with a ramp
portion 62 to facilitate, enhance, and maintain liner
engagement and/or to inhibit or prevent coring of the
mill. Preferably a space 63 is left between a blade
surface (or surfaces of inserts 65) and the milling
matrix material 60 to provide a fluid flow course
therethrough. Milling inserts 65 as desired may be
applied to the blades 59:
In one aspect the coupling bushings 36 are spaced-
apart about ten feet and the tubular string 34 has an
outer diameter of about 4 inches. In one aspect the
coupling bushing's inner diameter is chosen so that the
tubular string 34 fits tightly within, yet is rotatable
within, the coupling bushings 36. In one aspect, known
spiral drill pipe and/or spiral drill collars (e.g. one
or more) are used adjacent and/or above the mill 32.
In one aspect the tubular liner 14 is positioned so that
a lowermost coupling bushing is near the top of the
window (in one aspect between two and three feet above
it) . In one aspect the tubular liner is installed, e.g.
as in Figure 1D, and a portion of the tubular liner above
the window is removed (e.g. by milling or with an
internal 'cutter) creating a stub .end in the wellbore. A
coupling bushing or suitable centralizer or stabilizer is
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emplaced on the stub end and then the milling system is
run into the wellbore, through the newly-emplaced
coupling bushing, and into the tubular liner.
Spiralled grooves may be provided in the outer
surface of the coupling bushings.
Figure 5A shows a shroud system 70 for excluding
earth formation 71 from an interface at a window 72 in a
wellbore casing 73 between a main bore 74 and a lateral
bore 75. A liner 76 has been emplaced in the lateral
bore 75 and a top 77 thereof does not extend upwardly to
the window 72. To prevent earth from the formation 71
from falling into the liner or the main wellbore (through
the window 71), a hollow shroud 78 with a plug 79 at a
bottom thereof having a ramped end 80 is inserted into
the lateral bore 75 so that the ramped end 80 matingly
abuts a corresponding ramped end 81 of a plug 82 in a top
end of the liner 76. Optionally a plug 83 seals off the
main bore 74.
In one aspect in the shroud system 70 of Figure 5A,
the liner 76 is run into the lateral bore and cut at a
length as shown in Figure 5A. Then the plug 82 is
installed in the liner 76 and the shroud 78 is moved down
into the lateral bore 75. If necessary, the shroud 78 is
rotated so the ramp 80 seats correctly against the ramp
81. The liner be installed with the plug 82 in place.
The plug 83 can be used with an orientation/location
apparatus to insure correct positioning of the shroud 78
for entry into the lateral bore 75. Cement 84 may be
installed around the shroud 78 and the liner 76. Cement
85 may be installed around the casing 73 (before or after
lateral bore creation or lateral bore cementing.)
In certain aspects, the shroud 78 is made of metal
(e. g. steel; zinc, bronze, and any alloys thereof),
fiberglass, plastic, or composite. The shroud 78 may be
solid or hollow, as may be the plugs 79 and 82.
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Optionally., following shroud installation, the area in
the main bore 74 adjacent the window 72 and some area
above and below the window 72 is cemented with cement 86.
If the shroud 78 is hollow, it is also cemented
interiorly. Then, to regain access to the lateral bore
75, the cement 86 above and in the window 72 is removed
or drilled out, as well as cement within the shroud 78
and the plugs 80 and 82. If the shroud 78 is solid, it
is drilled through. If it is desired to r'e-establish
flow through the main bore 74 below the window 72, the
cement 86 above, adjacent and below the window 72 is
removed or drilled through, as well as the plug 83. The
plugs 80 and 82 may be solid or hollow.
In an alternative shroud system, rather than a 'plug
on the lower end of the shroud entering a liner, a ring
on the lower end of the shroud is positioned over the
liner top and sealingly encompasses it.
Figure 8 shows a mill 90 (e. g. usable in the milling
system 30, Figure 1D, as the mill 32) connected to a
tubular string 91 (like the string 34, Figure 1D) in a
liner 92 in a casing 93 in a wellbore 94. The mill 90
has downwardly projecting skirt 95 which defines a void
area 96. The skirt 95 is dressed with tungsten carbide
inserts 99 (e.g. but not limited to those disclosed in
U.S. Paterit 5,626.,189 and U.S. Patent 5,908,07.1 both co-
owned with the present invention. Roman numerals 'I, II,
III show three different positions of the mill 90. In
position I the mill 90 has not yet contacted the liner 92.
In position II, the mill 90 has milled an initial ledge 97
in the liner 92. In the position IIT, the mill 90 has
milled an opening 98 in the liner 92 (also shown in Figure
9). In position IT, in one aspect, a lower coupling
bushing (e.g. as in Figure 1D or 3B) close to the mill by its
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contact with the string 91 inhibits the mill's tendency
to deflect away from the liner 92 ( i . a . to the right in
Figure 8. In position III, the lower portions 95 of the
mill 90 inhibit the mill from stepping off the ledge 97
and from re-entering the liner 92. The lower portions 95
facilitate movement of the mill 90 down the curve of the
liner 92. A ramp portion 95a inhibits or prevents coring
of the mill.
Figure 10 shows a mill 300 according to the present
invention with a body 302 and a plurality of blades 304.
Associated with each blade 304 is a taper member 306
which is secured to the body 302, or to the blade 304, or
to both, either with an adhesive such as epoxy, with
connectors such as screws, bolts, or Velcro D straps or
pieces, or by a mating fit of parts such as tongue-and-
groove. The taper members may be made of any suitable
wood, plastic, composite, foam, metal, ceramic or cermet_
In certain embodiments the taper members are affixed to
the mill so that upon contact of the lower point of the
mill blades with the casing. to be milled, the taper
members break away so that milling is not impeded.
Figure 11 shows a mill 330 according to the present
invention with a body 332 and a plurality of blades 334.
A taper device 336 is secured around the mill 330 or
formed integrally thereon. The taper device 336 extends
around the entire circumference of the mill 330 beneath
the blades 339 and facilitates movement of the mill 330
through tubulars. The taper device 336 may be a two
piece snap-on or bolt-on device and may be made of the
same material as the taper member 306.
Figure 12 shows a blade-taper member combination
with a blade 340 having a groove 342 and a taper member
344 with a tongue 346. The tongue 346 is received in the
groove 342 to facilitate securement of the taper member
344 to the blade 340. Optionally, an epoxy or other
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adhesive may be used to glue the taper member to the
blade, to a mill body, or to both. The tongue and groove
may be dovetail shaped.
Figure 13 shows a blade-taper member combination
with a blade 350 and a taper member 352 with a recess
354. The blade 350 a.s received in and held in the recess
354. Optionally an adhesive may be used to enhance
securement of the taper member 352 to the blade, to the
mill, or to both.
Figure 14A shows a mill body 370 like the bodies of
the mills shown in Figure 5A, 10, and 11, but with a
series of grooves 372 therein which extend longitudinally
on the mill body and are sized, configured, and disposed
to receive and hold a taper member as shown in Figure 10,
Figure 12, or Figure 13_ Such a mill body may be used
instead of or in combination with any previously-
described taper securement means_
Figure 14B shows a mill body 380 like the bodies of
the mills shown in Figs. 5A, 10, and 11, but with a
series of dovetail grooves 382 therein which extend
longitudinally on the mill body and are sized,
configured, and disposed to receive and hold a taper
member as shown in Figure 10, Figure 12, or Figure 13.
Such a mill body may be used instead of or in combination
with any previously-described taper securement means.
Figure 15A shows a mill 100 usable as the mill in
any system described herein which has a cylindrical mill
body 101 to which is releasably secured a circular ring
102 that tapers from top to bottom with a taper 103.
Shearable pins or bolts 104 releasably hold the ring 102
to the mill body 101. The ring 102 is sized to
facilitate passage of the mill 100 through a tubular
member and also to inhibit undesired abutment of the mill
100 on an edge or surface of a coupling bushing, e.g. as
a system as in Figure 1D is moved down through the
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coupling bushings 36. Upon contact of the ring 102 with
a top of a coupling bushing, the pins 104 shear and the
mill 100 - which is now positioned of the top entry into
the coupling bushing due to the position of the ring 102
- easily enters the coupling bushing.
Figure 15B shows a mill 110 usable as the mill in
any system described herein which has a cylindrical mill
body 111 to which is releasably secured a ring 112 that
tapers from top to bottom with a taper 113. Shearable
pins or bolts 114 releasably hold the ring 112 to the
mill body 111_ The ring 112 is sized to facilitate
passage of the mill 110 through a tubular member and also
to inhibit undesired abutment of the mill 110 on an edge
or surface of a coupling bushing, e.g. as a system as in
Figure 1D is moved down through the coupling bushings 36.
Upon contact of the ring 112 with a top of a coupling
bushing, the pins 114 shear and the mill 110 - which is
now positioned of the top entry into the coupling bushing
due to the position of the ring 112 - easily enters the
coupling bushing.
Figure 15C shows a mill 120 usable as the mill in
any system described herein which has a cylindrical mill
body 121 to which is releasably secured a circular
cylindrical ring 122_ Shearable pins or bolts 124
releasably hold the ring 122 to the mill body 121. The
ring 122 is sized to facilitate passage of the mill 120
through a tubular member and also to inhibit undesired
abutment of the mill 120 on an edge or surface of a
coupling bushing, e.g. as a system as in Figure 1D is
moved down through the coupling bushings 36. Upon
contact of the ring 122 with a top of a coupling bushing,
the pins 124 shear and the mill 120 - which is now
positioned of the top entry into the coupling bushing due
to the position of the ring 122 - easily enters the
coupling bushing. In one aspect, the rings remain in the
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wellbore. In certain aspects, the rings are made of
steel, brass, phenolic, composite, plastic, metal, or
fiberglass.
As any of the mills shown in Figs. 15A - 15C move
down into the coupling bushing and further downwardly,
the rings 102, 112, and 122 remain atop a coupling
bushing and the mill (and related tubulars) move through
the ring.
In one aspect the rings are held with shear pins
which shear in response to about 500 to 6000 pounds of
force, and, in one aspect, about 4000 pounds of force.
Shearing of a ring 102, 112, or 122 gives a positive
indication at the surface of a precise location in the
wellbore and, in certain aspects, a known location at a
point above and near the area at which milling will
commence.
The mills of Figs. 15A - 15D represent schematically
any suitable known mill. Such a mill may be dressed with
any known milling matrix material and/or milling inserts
in any known array, pattern or configuration by any known
application method.
The rings 102, 112, and 122 as shown completely
encircle and encompass the cylindrical mill bodies with
which they are associated. In certain embodiments
acceptable centering of a mill is achieved by a partial
ring (e. g. that encompasses about 180 degrees or about
270 degrees of the mill body's circumference) or by
individual blocks whose cross-section appears like the
cross-sections of the rings in Figs. 15A - 15C, but which
are spaced apart around the mill body. in certain
aspects two, three, four or more such blocks are used
with a width, as viewed from above of between about one
to about ten inches.
Figure 15D shows a mill 126 with a cylindrical mill
body 125 having a lower concave face 128 having
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relatively sharp corners 127_ Any mill in Figs. 15A -
15D (and any mill disclosed herein) may be dressed with
any known matrix milling material, rough or ground
smooth; any known milling inserts in any known pattern,
array, or combination; any combination thereof: and/or
with milling inserts projecting out from and beyond
matrix milling material.
Figure 16A shows a system 200 with a tubular member
202 having a top end 204 with an anchor 206 and a bottom
end 208 with a plug, (preferably drillable) 210. An
- anchor may be provided at the end 208. A bar, whipstock,
or diverter 212 is secured at a lower end of a pre-formed
or pre-machined window 214 to and within the tubular
member 202.
A sleeve 220, e.g. a liner or wellbore tubular,
(made e.g. of metal, brass, bronze, zinc, zinc alloy,
aluminum, aluminum alloy, fiberglass, or composite) is
releasably secured in or is inserted into and through the
tubular member 202. The sleeve 220 is moved down to
contact the diverter 212 which urges the sleeve 2~0 to a
position as shown in Figure 16B (e. g. into an ,already
underreamed formation portion or into a lateral bore
extending from a main wellbore.
When the sleeve 220 is in the position shown in
Figure 16B an activatable sealing material 222 disposed
around the edge of the window 214 is activated to effect
sealing securement of the sleeve 220 at the window 214.
Preferably a flange 224 formed of or secured to the
sleeve 220 extends interiorly beyond the edge of the
window 214 to facilitate sealing of the sleeve at the
window and to serve as a stop and locking device.
Any suitable stored energy medium may be used as the
sealing material 222, including, but not limited to,
thermite and other iron oxide-aluminum compounds which
react to form a metal seal or weld between parts and
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which are activated by heat with suitable initiation
devices as are- well known in the art indicated
schematically by the device 221, Figure 16E.
In one aspect, not shown, the sleeve 220 has an open
lower end. As shown in Figs. 16A and 16B a pressure
containing drillable shoe or end cap 226 seals off the
sleeve's bottom end.
In one aspect the da:verter 212 is replaceable or
removable in the wellbore or at the surface . The sleeve
220 may be any desired length.
As shown in rFigure 16E a sleeve 240 (like the sleeve
220) with a flange 241 has been installed at a pre-formed
window 244 of a tubular body 246 installed in a casing
248 of a wellbore 250 extending from an earth surface
down in an earth formation 252 and sealed in place with
sealing material 243. A top anchor 259 anchors the top
of the tubular body 246 in casing 248. A diverter 242
secured within the body 246 (removable or not) has urged
the sleeve 240 into an underreamed part of the formation
252 and a liner 256 has been inserted into and through
the sleeve 240. The liner 256 (any desired length)
extends down into a lateral wellbore 258. A liner hanger
or packoff liner hanger 260 is at the top of the liner
256. The liner may be cemented into place with cement
262. An anchor 255 anchors the bottom of the tubular
body 246. Alternatively a plug may be used instead of,
or in addition to, the anchor 255.
In one aspect a system with a sleeve as shown in
Figure 16A or 16E is run in a well and set, or bridged,
across an already milled and under-reamed portion of
casing. The sleeve is then pushed down to the diverter
and forced out the pre-machined window in the tool body.
In this position, the flange on the sleeve is adjacent to
a shoulder in the pre-machined window and positioned in
place. The stored energy medium reaction is then
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initiated creating a pressure-containing seal between the
flange and the tool body. At this point, a lateral open
hole may be drilled or an existing lateral open hole may
be lengthened. An additional length of liner may be run
into the drilled open hole and hung off the sleeve and
then cemented into place.
Alternatively, the lateral open hole is first
drilled and~then an entire liner string with a flange on
top (like, e.g. the flange 241, Figure 16E) is run into
place. A seal is then activated (as with the systems of
Figs. 16A and 16E with sealing material 222 or 243). If
desired, the liner is then cemented in place.
In another embodiment, a system as in Figs. 16A or
16E is run into a new well (without a sleeve or liner in
place within the tool body) by placing the tool body
directly in a new casing string while running in hole,
with slight modifications (e.g. no anchors or plugs are
needed) to the tool body. The aforementioned procedures
are then followed, with the absence of section milling
and under-reaming.
Figure 17 shows a mill system 400 according to the
present invention which includes a tubular member 402
with a lower box end 404 and a flow bore 406 from a
bottom end 408 to a top end 410. Stabilizers may be
emplaced around a tubular 402 or the tubular 402 with
stabilizers may be one piece. Three stabilizers 411,
412, 413 may be integrally formed of or the tubular 402,
e.g. by welding. In one aspect the stabilizers consist
of hardface material welded to the tubular body. Spiral
grooves 419 extend from the top to the bottom of each
stabilizer which define spiral portions 414 of each
stabilizer. Optionally, these spiral portions are
dressed with crushed carbide 416 or other suitable
hardfacing, matrix milling material, and/or milling
inserts_
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A mill 420 is connected to the -lower end 408 of the
tubular member 402 and fluid is flowable through the flow
bore 406 to and through the mill 420. In one particular
specific embodiment, described here by way of
5 illustration and not limitation, the outer diameter of
the tubular member 402 is about 4.000 inches; each
stabilizer 411, 412, 413 is about three feet long; each
space 418 between stabilizers is about ten inches; the
distance from the bottom of the stabilizer 411 to the top
10 of the mill 420 is about four feet; the distance from the
bottom end of the mill 420 to the top of the stabilizer
411 is about fifteen feet; and the distance from the
bottom of the stabilizer 413 to the top end of the
tubular member 402 is about twelve feet. This particular
15 specific embodiment of a system 400 may be used with five
inch special drift casing with the spiral portions 414
extending outwardly slightly beyond the 4.369 inch drift
diameter limit. The spiral portions 414 will ream any
portion within the casing up to the 4.375 inch size (e. g.
20 the casing is about 4.369 inches and the stabilizer
blades are at 4_375 inches).
Figs_ 18A and 1BB show the mill 420 with a generally
cylindrical body 422 having a flow bore 424 extending
from a top end 426 down to a lower exit port 428. One or
25 more side flow ports 430 entrance the movement of
cuttings and debris away from a plurality of spaced-apart
milling blades 432 which are dressed with inserts 434.
In the embodiment shown there are three ports 430 equally
spaced around the body 422. Any suitable known inserts
30 may be used in any suitable known pattern or array for
the inserts 434 and/or matrix milling material may be
used on the blades. In one aspect the blades 432 of the
mill 420 at the lower end of the mill extend outwardly to
a larger diameter than an upper part of the body 422.
35 The lowermost unserts on the blades can achieve an
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- 22 -
aggressive point or small area contact with the tubular
to be milled through. Such difference in diameter also
facilitates fluid flow from the bottom of the mill
upwardly.
S A recess 436 in the lower part of the body 422 an
amount 438 of the crushed carbide therein (e. g. welded
in) whose lower surface 440 is generally cone-shaped to
facilitate correct positioning of the mill on casing
being cut and' to urge the mill toward the parent bore
once an initial cut out is achieved through the liner and
urged toward the lateral at the bottom of the window
' creating a longer wiizdow. Thus the mill maintains its
position so it cuts the lateral liner and so slipping
around the bend in the lateral liner is inhibited.
Spaces 442 between blades provide for fluid flow_ A
portion 444 of the bore 424 is shown as vertical
(straight) but it may be canted with respect to the bore
424. Alternatively any of the bore configurations
disclosed herein including but not limited to tho.>e in
Figs. 4E and 4G, may be used in the mill .420.
Figure 19 shows five steps, 1 - 5, in a milling
operation according to the present invention .with a
system 400 as shown in Figure 17. In step 1, (see
enlarged portion in Figure 19B) the system 400 has been
introduced from the surface on a rotatable tubular string
450 with a stabilizer or crossover sub so that the mill
420 a.s approaching the beginning of a bend 452 in a liner
. 454 which lines a lateral wellbore 456 (see Figure 19C)
extending laterally from a primary wellbore 458 cased
with casing 460_ The liner 454 may ba made of special
drift tubulars. Prior to liner installation, the
whipstock is removed. The primary and lateral wellbores
are shown only in Figure 19C but are present with the
system as shown in Figure 19 and Figs_ 19A, 19B, 19D and
19E. The liner 454 in one aspect extends to a point
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above the top stabilizer 411 in the wellbore as shown in
Figure 19.
In step 2 (see enlarged .portion in Figure 19A) the
mill 420 is lowered further and is beginning :to enter the
bend 452 of the liner 454 at which milling has commenced.
In step 3 (see enlarged portion in Figure 19C) the mill
920 has been lowered so that the lower edge of the blades
432 contacts the liner 454 at the location of milling.
The stabilizer 411 is still wholly within a straight
portion of the liner 454. The top of liner 454 may be in
any desired location, e.g. but not limited to between ten
and two hundred feet above the window location to assist
in holding the mill 420 against that portion of the liner
454 to be milled through and to prevent the mill 420 from
entering the lateral wellbore 456.
In step 4 (see enlarged portion in Figure 19D) in an
initial cut out the mill has broken through the outer
diameter of the liner and the first stabilizer has begun
to move into the bend area.
In step 5 (see enlarged portion in Figure 19E) the
mill 420 has milled through the liner 454 reestablishing
communication through the primary wellbore 458 from above
the system 400 to below the system 400. The system 400
is then removed from the wellbore. Additional milling or
reaming may be done with any suitable tool.
In certain embodiments of the particular specific
embodiment of the system 400 previously described (i.e.,
the particular embodiment with spaces 418 about ten
inches long, etc. ) , the distance from the bottom of the
mill to the lower end of the lowest stabilizer 411 ranges
between 0 and 5 feet and preferably between 0 and 4 feet;
the stabilizer 413 ranges a.n length between 24 and 48
inches (as do the other stabilizers 411 and 412); and the
length (height) of the spaces 418 ranges between 8 and 14
inches. It is preferred in certain embodiments that the
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system 400 be sufficiently stiff that the lower end of
the mill 420 deflects no more than about .4 inches from
the axis of the system 400 and preferably no more than
about .3 inches from this axis.
Figure 20 illustrates a "single-trip" modification
for the system of Figure 17 (and for any system disclosed
herein) with which a liner L (like the liner 954, Figure
19) is releasably suspended from the tubular 402 by a
liner hanger H shear-pinned to the tubular 402 with shear
pins P_ The system as shown in Figure 20 (and Figure 17)
is run into a wellbore so that the liner enters a desired
lateral wellhore and is properly positioned. Then force
is applied to the shear pins P to release the tubular 402
and mill 420. Rotation of the string to which the
tubular 402 is attached (which string extends to earth
surface) rotates the mill to mill the liner L.
