Problem
Large-diameter casing exit systems are prone to fatigue failure due to extreme cyclic stresses during window milling. Conventional designs often break down mid-operation, leading to unplanned NPT, tool recovery, and increased P&A costs—undermining the promise of “one-trip” efficiency.
Solution
Designed and field-proven a fatigue-resistant one-trip casing exit system featuring:
Large radiused transitions to reduce stress concentration at material upsets,
A novel peak-like load distribution structure for oversized tools,
Vibration-minimizing features integrated into the whipstock body for smoother exits.
Impact
✅ Multiple successful runs in North Sea, Gulf of Mexico, Middle East & Asia Pacific
✅ Consistent one-trip success rate, even in large casing sizes
✅ Improved operator confidence and profit margins
Patents Referenced
Problem
Many P&A regulations—especially in the North Sea and Gulf of Mexico—require a rock-to-rock barrier, which demands the removal of multiple concentric casing strings to set a competent cement plug against formation.
However, larger casings cannot be milled without first removing the smaller-ID production riser, a time-consuming process that adds costly rig time and operational complexity.
Solution
Engineered and deployed a section mill capable of passing through the restricted ID of a production riser, then:
Expanding its arms far beyond conventional reach to mill a section in the larger casing below,
Milling concentrically through two or more casing strings, creating a window in both inner and outer casings from a single BHA pass.
This section-in-section milling capability eliminated the need to remove the riser altogether.
Impact
✅ Enabled rock-to-rock barrier creation without riser removal
✅ Substantially reduced non-productive rig time
✅ Successfully deployed in deepwater Gulf of Mexico operation
✅ Delivered a significant reduction in total P&A cost
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Reduce P&A Cost with Section Milling Technology (IADC/SPE-178827-MS)
Problem
Conventional plug and abandonment workflows typically involve three trips:
Set a mechanical or composite base plug
Cut and retrieve the casing above the plug
Place a cement barrier across the wellbore
Each trip adds rig time, increases operational risk, and drives up overall abandonment cost, especially in offshore environments.
Solution
Developed the Pump-Through Casing Cutter, a fully integrated one-trip solution that:
Sets the base plug
Cuts and retrieves the casing
Pumps through cement to place a competent rock-to-rock plug
This hydraulically activated tool regulates internal flow to execute each operation in the correct sequence. The cutter delivers clean 360° casing cuts, maintains full circulation, and enables cement placement—all without tripping out.
Impact
✅ Condensed a 3-trip P&A process into a single, efficient run
✅ Reduced rig time, logistics, and HSE exposure
✅ Proven in field deployments across offshore P&A campaigns
✅ Now adopted as a company standard for casing recovery in single-trip abandonment
Problem
When performing upward section milling, there's a risk that the mill blades may get lodged in the casing wall and fail to retract. In such cases, the bottomhole assembly (BHA) becomes stuck and cannot be pulled out, risking a costly fishing operation or sidetrack.
Solution
Engineered an Emergency Disconnect tool that:
Is installed directly above the section mill in the BHA
Hydraulically or mechanically severs a designed break section
Separates the stuck mill from the BHA, allowing recovery of the upper assembly
The tool is activated either by applied hydraulic pressure or tensile overpull, depending on the operational requirement. This enables controlled and predictable disconnection when retrieval becomes impossible.
Impact
✅ Provides a fail-safe mechanism during high-risk milling operations
✅ Reduces the risk of extended NPT and fishing operations
✅ Improves operational safety and planning for upward milling runs
✅ Enables quick recovery of BHA components, minimizing cost and complexity
Problem
In formations with a dense network of horizontal wells, sidetracking upward increases the risk of intersecting existing laterals. To avoid this, operators aim for a lowside casing exit, using gravity to drill away from the crowded upper bore space.
However, in horizontal wells, conventional whipstocks sag under their own weight. This causes the tip of the whipstock to obstruct the milling or drilling assembly, making low-side exits unreliable or impossible.
Solution
Developed a releasable, rotational anchor system that:
Orients the whipstock face toward the low side of the wellbore
Applies controlled tilt to the whipstock while locking it in place
Prevents the tip from sagging, even in fully horizontal wells
Enables clean, unobstructed passage of milling and drilling BHA along the whipstock ramp
Impact
✅ Enabled gravity-assisted lowside casing exits in densely drilled fields
✅ Reduced the risk of wellbore collision in sidetracking operations
✅ Provided a mechanically simple yet highly effective solution for horizontal exits
✅ Successfully deployed in environments with limited clearance and high lateral density
Problem
Sidetracking in open hole (uncased) sections is typically performed near the bottom of the well, where tools can be left behind. These operations require cost-efficient systems due to their disposable nature.
However, in high-angle wells or those with tight doglegs, whipstocks often encounter resistance during deployment, getting wedged in the open hole and becoming stuck due to repeated pushing and pulling.
Solution
Developed a complete openhole sidetracking system consisting of:
A robust whipstock deployment tool capable of withstanding mechanical impact
A releasable connection to the whipstock to manage retrieval or disconnection as needed
A cost-efficient whipstock and anchor designed specifically for openhole operations, without compromising mechanical integrity
The system was engineered for durability, smooth deployment, and affordability, making it ideal for disposable sidetracking applications.
Impact
✅ Standardized as the go-to system for openhole sidetracks
✅ Reduced risk of tool sticking during deployment
✅ Balanced mechanical robustness with cost efficiency
✅ Widely adopted for bottomhole sidetracks in openhole environments
Problem
Milling through composite bridge plugs requires a precise balance of fluid flow:
Enough flow through the motor to generate torque and drive the mill
But also controlled annular flow to carry debris and manage hole cleaning
Unregulated flow can lead to motor stalling, inefficient milling, or poor cuttings transport.
Solution
Developed a flow-diverting tool equipped with tungsten carbide jet nozzles, designed to:
Restrict and redirect flow through calibrated jets
Deliver consistent and optimized flow rates to the motor and annulus
Ensure efficient plug milling performance across a wide range of flow regimes
Additionally, created an MS Excel-based flow rate calculator to:
Predict flow splits based on surface input
Help field engineers fine-tune pump rates for optimal milling conditions
Impact
✅ Became a standard tool in composite plug milling operations
✅ Improved milling efficiency and motor reliability
✅ Reduced fluid waste and plug removal time
✅ Enabled predictable job planning with digital flow calculator