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Trackmaster Whipstocks Wellbore Departure Systems Operating Instructions

ES20.39754B

Table of Contents 1.0

2.0

3.0

4.0 5.0

Introduction.......................................................................................................................................1 1.1 Trackmaster Wellbore Departure Systems .........................................................................1 1.2 Innovative Features.............................................................................................................2 1.2.1 Multi-Ramp Whipstock ........................................................................................2 1.2.2 Mill/Whip Hook-up ..............................................................................................2 1.2.3 Whipstock System Retrieval ................................................................................3 1.3 Trackmaster Anchor Systems ............................................................................................3 1.3.1 Trackmaster Hydraulic Anchor ............................................................................3 1.3.2 Trackmaster Hydraulic Anchor with Pack-off Element .......................................4 1.3.3 Trackmaster Mechanical Anchor..........................................................................4 1.3.4 Trackmaster Inflatable Anchor.............................................................................4 1.3.5 Trackmaster Expandable Anchor .........................................................................5 1.4 The Trackmaster Mills.......................................................................................................5 1.4.1 Trackmaster Carbide Tri-Mill ..............................................................................5 1.4.2 Trackmaster FasTrack Tri-Mill ............................................................................6 1.4.3 Trackmaster Hard Formation Bi-Mill...................................................................6 1.4.4 Trackmaster GeoTrack Mill .................................................................................7 1.5 Hydraulic Running Tool .....................................................................................................7 1.6 Non Advancing Multi-Cycle By-Pass Valve ......................................................................7 1.7 Retrievable Features ...........................................................................................................8 1.7.1 Hook Assembly Retrieval Tool ............................................................................8 1.7.2 Die Collar Assembly Retrieval Tool ....................................................................8 Equipment for Sidetrack ...................................................................................................................9 2.1 Shop Tools Required ..........................................................................................................9 2.2 Recommended Spares and Redress Kit ..............................................................................9 2.3 Bottom Hole Assembly Components................................................................................10 2.3.1 Well Preparation.................................................................................................10 2.3.2 Sidetrack.............................................................................................................10 2.3.3 Retrieval .............................................................................................................10 2.4 Service Facility Checks ....................................................................................................10 Preparation for Sidetrack ................................................................................................................12 3.1 Equipment.........................................................................................................................12 3.2 Well Preparation ...............................................................................................................12 3.3 Milling Fluid Guidelines...................................................................................................13 3.4 Non-Advancing Multi-cycle Bypass Valve Test Procedure .............................................14 Trackmaster System Make up Procedure........................................................................................16 Running Procedure..........................................................................................................................18 5.1 Run the Whipstock Assembly...........................................................................................18 5.2 Orient the Whipstock Assembly .......................................................................................18 5.3 Set the Whipstock Assembly ............................................................................................19 5.3.1 Trackmaster Hydraulic Anchor ..........................................................................19 5.3.2 Trackmaster Expandable Anchor .......................................................................19 5.3.3 Trackmaster Mechanical Anchor........................................................................19 5.4 Break the Mill from the Whip...........................................................................................20 5.4.1 Trackmaster Hydraulic Anchor ..........................................................................20 5.4.2 Trackmaster Expandable Anchor .......................................................................20 5.4.3 Trackmaster Mechanical Anchor........................................................................20 5.5 Mill the Window...............................................................................................................21 5.6 Drill the Rathole ...............................................................................................................22 5.7 Pull Out of the Hole ..........................................................................................................22 5.8 Drilling Recommendations ...............................................................................................22

ES20.39754B Operating Instructions

i of ii

®

Trackmaster Plus Wellbore Departure Systems Confidential Property of Smith International, Inc.

6.0

7.0

Retrieving the Whipstock Assembly...............................................................................................23 6.1 Hook Assembly Retrieval Tool ........................................................................................24 6.2 Die Collar Assembly Retrieval Tool.................................................................................24 6.3 Sheared Hinge Pin ............................................................................................................26 Best Make up Practices for the Trackmaster Whipstock Assembly................................................27

List of Figures Figure 1 Trackmaster Wellbore Departure Systems ......................................................................................................1 Figure 2 Whip to Mill Head Hookup.............................................................................................................................3 Figure 3 Trackmaster Hydraulic Anchor .......................................................................................................................3 Figure 4 Trackmaster Hydraulic Anchor with Pack-off Element ..................................................................................4 Figure 5 Trackmaster Mechanical Anchor ....................................................................................................................4 Figure 6 Trackmaster Inflatable Anchor........................................................................................................................4 Figure 7 Trackmaster Expandable Anchor ....................................................................................................................5 Figure 8 Trackmaster Carbide Tri- Mill ........................................................................................................................5 Figure 9 Trackmaster FasTrack Tri-Mill .......................................................................................................................6 Figure 10 Trackmaster Hard Formation Bi-Mill ...........................................................................................................6 Figure 11 Trackmaster GeoTrack Mill ..........................................................................................................................7 Figure 12 Multi-Cycle By-Pass Valve...........................................................................................................................7 Figure 13 Hook Retrieval Tool......................................................................................................................................8 Figure 14 Die Collar Assembly Retrieval Tool .............................................................................................................8

List of Tables Table 1 Recommended Spares and Redress Kit ............................................................................................................9 Table 2 Torque Specifications .....................................................................................................................................11 Table 3 Flow Rate to Close Non Advancing Multi-Cycle By-Pass Valve ..................................................................15 Table 4 Approximate Break Bolt Shear Values (Standard).........................................................................................20 Table 5 Approximate Break Bolt Shear Values (Standard).........................................................................................20 Table 6 Set Down Loads and Approximate Break Bolt Shear Value (Standard) ........................................................21 Table 7 Recommended Milling Parameters.................................................................................................................21 Table 8 Whipstock Assembly Retrieving Specifications with Hydraulic Set Anchor or Mechanical Set Anchor ......23 Table 9 Whipstock Assembly Retrieving Specifications with Expandable Anchor ....................................................23 Table 10 Shear Values for the Hinge Pins and Fishing Neck Dimensions ..................................................................26

ES20.39754B ii of ii Operating Instructions Confidential Property of Smith International North Sea Ltd.

Trackmaster Whipstocks Wellbore Departure System

Section 1 1.0

Introduction 1.1

Trackmaster Wellbore Departure Systems The Trackmaster Wellbore Departure Systems represents an application specific and results driven approach to one-trip reliability and cost optimization (Figure 1). The running assembly consists of a mill and whipstock assembly. The anchor subassembly can be a retrievable hydraulic anchor, a mechanical anchor, and an open hole inflatable anchor or expandable hydraulic anchor. All Trackmaster Anchors are retrievable. The objective of the Trackmaster Wellbore Departure Systems is to accomplish the following steps in a single trip:

Figure 1 Trackmaster Wellbore Departure Systems

•

Run the whipstock and milling assembly

•

Orient the whipstock assembly with Measuring While Drilling (MWD) tool or Gyroscope

•

Set the anchor

•

Release the mill from the whip

•

Mill the window

•

Drill the rathole or lateral

•

Pull out of hole

The result is a full size usable window achieved within a minimum of milling time with safe and easy passage for the required drilling assembly.

DATE: March 30, 2004

INDEX ES20 Operating Instructions

DRAWN: CSL APRVD: JM This drawing and data embody proprietary information which is the confidential property of Smith International and which shall not be copied, reproduced, disclosed to others, or used in whole or in part for any purpose, without the written permission of Smith. This drawing is loaned in confidence with the understanding that it shall be returned on demand.

B

22414

04/30/04

gm

A

22346

04/07/04

gm

–

22294

03/30/04

JM

REV

ECO

DATE

BY

1 of 32

Trackmaster Wellbore Departure Systems

SPEC. NO. ES20.39754

Introduction

Section 1

The whipstock assembly may be oriented and set at any depth. It should be located immediately above a casing collar to provide a smooth I.D. in which to set the anchor and mill the window. A surveying system should be run with the Trackmaster Wellbore Departure Systems to determine the preferred orientation for the sidetrack. When orientating in a specific direction and if a hole angle of more than two degrees exits at the setting depth, then it is recommended that the whipstock assembly be set 0 – 90 degrees to the right or left of high side of the hole. With small modifications the Trackmaster Wellbore Departure Systems can be configured to exit from low side of the hole. After setting the anchor, either hydraulically or mechanically, a load is applied to the drill string to shear the break bolt between the mill and whip. At this point, string rotation may begin for milling of the window, followed by drilling of the rathole. 1.2

Innovative Features 1.2.1 Multi-Ramp Whipstock All Trackmaster Whipstock Systems utilize a multiple angle whip design to deliver a high-quality useable window. The combination of ramp angles maximizes milling efficiency, prolongs window mill life and produces an optimum dogleg through the window. •

Fast Cutout Ramp Facilitates mill/whip hook-up point Initiates rapid casing cutout Produces full gauge window within a few inches of cutout

•

Full Gauge Section Maintains the full gauge window section Useable window length can be customized Thicker cross section for optimized performance

•

Mid-Ramp Section Accelerates the mill past its center point Improves one-trip mill performance

1.2.2 Mill/Whip Hook-up All Trackmaster Whipstock Systems use the latest window mill to whipstock attachment technology. The new mill/whip hook-up is designed to provide higher torque values while delivering the same reliable shear performance. This non-threaded retention system allows up to 3 degrees of flex between the milling assembly and the whipstock to facilitate passage through high doglegs in the wellbore. See Figure 2. Trackmaster Whipstocks 2 of 32 Wellbore Departure Systems Confidential Property of Smith International North Sea Ltd

ES20.39754B Operating Instructions

Section 1

Introduction

•

Higher torque tolerance

•

Increased flexibility through wellbore doglegs

•

Enables higher lead mill cutter density

Figure 2 Whip to Mill Head Hookup

Mill Head Rubber Grommet Whip

Locking Pin

Break Bolt

1.2.3 Whipstock System Retrieval All Trackmaster Expandable, Hydraulic, and Mechanical Anchors are retrievable. The hook retrieval system is the primary method, utilizing a retrieving tool with an integral hook geometrically matched to a slot machined in the whip.

1.3

•

Manufactured from high strength alloy steel

•

Interlocking geometric profiles couple together securely

•

High retrieval load capacity

Trackmaster Anchor Systems 1.3.1 Trackmaster Hydraulic Anchor The Trackmaster Hydraulic Anchor locks the whipstock assembly to the casing. It is hydraulically set with 3,000 to 3,500 psi pressure. The function of the anchor is to absorb axial and torsional loads during milling. See Figure 3. Figure 3 Trackmaster Hydraulic Anchor

ES20.39754B Operating Instructions

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Trackmaster Whipstocks Wellbore Departure Systems Confidential Property of Smith International North Sea Ltd.

Introduction

Section 1

1.3.2 Trackmaster Hydraulic Anchor with Pack-off Element The Trackmaster Hydraulic Anchor with Pack-off Element is run and set in a single trip, just as the Trackmaster Hydraulic Anchor. This system provides isolation from the lower wellbore using an integral packer. It can hold 5,000 psi in both directions. See Figure 4. Figure 4 Trackmaster Hydraulic Anchor with Pack-off Element

1.3.3 Trackmaster Mechanical Anchor The Trackmaster Mechanical Anchor requires a plug in the wellbore to initiate setting. Patented tongue-and-pocket slip design ensures full, centralized slip contact, providing superior anti-rotation and bi-directional loading capabilities. See Figure 5. Figure 5 Trackmaster Mechanical Anchor

1.3.4 Trackmaster Inflatable Anchor The Trackmaster Inflatable Anchor is run, oriented, and hydraulically set in a single trip. Patented element design enables the anchor to set in open holes and provides adequate torque resistance needed for milling or drilling. See Figure 6. Figure 6 Trackmaster Inflatable Anchor

Trackmaster Whipstocks 4 of 32 Wellbore Departure Systems Confidential Property of Smith International North Sea Ltd

ES20.39754B Operating Instructions

Section 1

Introduction

1.3.5 Trackmaster Expandable Anchor The Trackmaster Expandable Anchor is run, oriented, and hydraulically set in a single trip. It can be released by a straight pull. The anchor has three slips located in the same housing and placed at 120 degrees spacing, providing maximum centralization and stability. See Figure 7. Figure 7 Trackmaster Expandable Anchor

1.4

The Trackmaster Mills 1.4.1 Trackmaster Carbide Tri-Mill The Trackmaster Carbide Tri-Mill (Figure 8) utilizes Smith Services' proven Millmaster™ carbide inserts augmented with crushed tungsten carbide for an immediate full gauge cut-out. The carbide inserts are designed with chip breakers to improve cuttings removal. The mill profile has been specifically designed to match the ramp angles of the Trackmaster Whip directing the milling energy efficiently into the casing and not the whip ramp. The Trackmaster Carbide Tri-Mill is a cost effective, reliable window mill. The mill provides a hydraulic path from the milling bottom hole assembly to the whip and anchor via a hydraulic hose. Figure 8 Trackmaster Carbide Tri- Mill

ES20.39754B Operating Instructions

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Trackmaster Whipstocks Wellbore Departure Systems Confidential Property of Smith International North Sea Ltd.

Introduction

Section 1

1.4.2 Trackmaster FasTrack Tri-Mill The Trackmaster FasTrack Tri-Mill (Figure 9) utilizes tungsten carbide cylindrical cutters and tungsten crushed tungsten carbide rather than conventional carbide inserts. The cylindrical cutters are made from Smith Services' proven Millmaster™ carbide grade inserts and will effectively exit the casing and cut through the formation to drill the required rathole. This new milling structure not only reduces overall casing exit time, it ensures a level of performance that can be duplicated casing exit after exit. The mill provides a hydraulic path from the milling bottom hole assembly to the whip and anchor via a hydraulic hose. Figure 9 Trackmaster FasTrack Tri-Mill

1.4.3 Trackmaster Hard Formation Bi-Mill The Trackmaster Hard Formation Bi-Mill is the result of a combined engineering effort between Smith Services and Smith GeoDiamond. The proprietary blend of synthetic diamond and cobalt has resulted in a PDC cutting structure capable of milling materials such as casing and drilling formations with compressive strengths greater than 20,000 psi. The Trackmaster Hard Formation Bi-Mill is capable of drilling 3 to 15 feet of rathole. It can be used as the lead mill on both bi-mill and tri-mill configurations. The mill provides a hydraulic path from milling bottom hole assembly to the whip and anchor via a hydraulic hose. For further information, refer to Trackmaster Hard Formation System Operating Instructions manual. Figure 10 Trackmaster Hard Formation Bi-Mill

Trackmaster Whipstocks 6 of 32 Wellbore Departure Systems Confidential Property of Smith International North Sea Ltd

ES20.39754B Operating Instructions

Section 1

Introduction

1.4.4 Trackmaster GeoTrack Mill The Trackmaster GeoTrack Mill (Figure 11) has an impact and wear resistant PDC cutting structure capable of milling materials such as casing, and drill an extended rathole in a single trip. The mill is designed for high penetration rates and steerability. The jet nozzles are placed strategically to ensure cutter cooling and good hole cleaning. New mill/whip hook-up enables maximum cutting structure coverage for improved drilling performance. For further information, refer to Trackmaster GeoTrack System Operating Instructions manual. Figure 11 Trackmaster GeoTrack Mill

1.5

Hydraulic Running Tool The Hydraulic Running Tool is run directly above the mill. A floating piston inside the tool separates the clean hydraulic fluid, used for setting the anchor, from the wellbore fluid. The piston does not restrict flow after setting anchor.

1.6

Non Advancing Multi-Cycle By-Pass Valve The Non Advancing Multi-Cycle By-Pass Valve (NAMCBPV) is run in the assembly when a hydraulic anchor is to be oriented and set in a well. It is positioned below the MWD tool. Fluid is circulated through the NAMCBPV to facilitate a MWD survey. Once the whipstock has been orientated, the tool is cycled through a predetermined sequence until a valve closes off the flow path to the annulus (Figure 12). Once closed, the string is pressured up to set the anchor. Figure 12 Multi-Cycle By-Pass Valve

ES20.39754B Operating Instructions

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Trackmaster Whipstocks Wellbore Departure Systems Confidential Property of Smith International North Sea Ltd.

Introduction

1.7

Section 1

Retrievable Features 1.7.1 Hook Assembly Retrieval Tool A whipstock assembly with a hook slot in the whip face can be retrieved with the hook assembly retrieval tool (Figure 13). The anchor can be a retrievable hydraulic anchor, mechanical anchor, or expandable hydraulic anchor. The tool has been designed to hook into the slot on the whip face and then a pull applied to release the assembly. A typical retrieval BHA would include a retrieval tool, full gage stabilizer, joint of drill pipe, surveying equipment, crossover, heavyweight drill pipe, and drill pipe. Figure 13 Hook Retrieval Tool

1.7.2 Die Collar Assembly Retrieval Tool A die collar assembly retrieval tool, consist of a die collar section designed to pull the whip and a cut lip guide, designed to lift the whip of the casing or tubing wall (Figure 14). A typical bottom hole assembly (BHA) for retrieval may consist of a retrieval tool, full gauge stabilizer, bumper sub, fishing jar, full gauge stabilizer, crossover, heavyweight drill pipe, and drill pipe. A safety joint and accelerator are used in some assemblies. Figure 14 Die Collar Assembly Retrieval Tool

Trackmaster Whipstocks 8 of 32 Wellbore Departure Systems Confidential Property of Smith International North Sea Ltd

ES20.39754B Operating Instructions

Section 2 2.0

Equipment for Sidetrack Caution:

2.1

Shop Tools Required •

Tool box with tote tray

•

•

11⁄2 inch open end adjustable wrench

Internal snap ring pliers (106 thru 175)

•

2 inch open end adjustable wrench

8 inch screwdriver – standard tip, 3⁄8 inch

•

8 inch screwdriver – narrow tip, 3⁄16 inch

•

3

⁄4 inch female x 1⁄2 inch male socket adapter

•

Allen wrench set (3⁄32 inch thru 1⁄4 inch)

•

Tap wrench

•

Thread locking compound

•

5 inch drive extension (3⁄4 inch drive)

•

2.2

Smith Services advises the use of tools and equipment called out in this manual to ensure safety during assembly, disassembly and testing of the Trackmaster Wellbore Departure System components.

•

2 inch pipe wrench

•

5

•

3

⁄8 inch hex key wrench

•

5

⁄8 inch hex key wrench

•

Two rolls of teflon tape

•

Breaker bar (3⁄4 inch drive)

•

Internal snap ring pliers (25 thru 31)

⁄16 inch pipe hex key wrench

Recommended Spares and Redress Kit The recommended spares and redress kit can be found on Table 1. Table 1 Recommended Spares and Redress Kit Description Control Line Hose Adapter Control Line Assembly Rubber Grommet Break Bolt Break-off Plugs Orifices & O-rings Running Tool Redress Kit Locking Pin

ES20.39754B Operating Instructions

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®

Trackmaster Plus Wellbore Departure Systems Confidential Property of Smith International, Inc.

Equipment for Sidetrack

2.3

Section 2

Bottom Hole Assembly Components 2.3.1 Well Preparation •

Review of collar locator log

•

Review of cement bond log

•

Casing scraper

•

Gage ring sub

2.3.2 Sidetrack •

Whipstock assembly -

Whipstock sub-assembly

-

Anchor sub-assembly -

Trackmaster Hydraulic Anchor

-

Trackmaster Hydraulic Anchor with Pack-Off Element

-

Trackmaster Mechanical Anchor

-

Trackmaster Inflatable Anchor

-

Trackmaster Expandable Anchor

•

Running Tool

•

Flex Joint-Heavyweight Drill Pipe (HWDP) or High Strength Drill Pipe

•

Non Advancing Multi-Cycle By-Pass Valve or Hi-Flow Bypass Valve

•

MWD or Orienting Sub for Gyroscope

2.3.3 Retrieval •

Retrieval tools Hook assembly Die collar assembly

2.4

•

Fishing jars

•

Bumper sub

•

Stabilizers

Service Facility Checks 2.4.1

The make up and fit between the whip and mill should be checked (and corrected if needed) at the shop prior to being sent to the job. The gage diameter of the connected whip and mill must be within the specified grind O.D. of the mill.

Trackmaster Whipstocks 10 of 32 Wellbore Departure Systems Confidential Property of Smith International North Sea Ltd

ES20.39754B Operating Instructions

Section 2

Equipment for Sidetrack

2.4.2

The whipstock assembly may be shipped to the service facility or job site in two pieces. Use the following torque specification for making-up the connection between the hinge connector and anchor sub-assembly (see Table 2). Table 2 Torque Specifications Hydraulic Anchor Size (in) 3

8 ⁄8 IF

3

5 ⁄2 IF

3

5 ⁄2 IF

5

5 ⁄2 IF

13 ⁄8 11 ⁄4 10 ⁄4 9 ⁄8 5

Torque (ft·lb)

5

60,000

1

40,000

1

40,000

1

40,000

7 ⁄8

4 IF

7

3 ⁄2 IF

18,000

1

15,000

7

6,500

5 ⁄2

1

2 ⁄8 IF

1

4 ⁄2

2 ⁄8 IF

4,500

Expandable Anchor (in)

Connection Size (in)

Torque (ft·lb)

3

3

13 ⁄8 x 20 5

5

60,000

1

40,000

1

8 ⁄8 IF

3

9 ⁄8 x 13 ⁄8

5 ⁄2 IF

5

7 x 9 ⁄8

3 ⁄2 IF

15,000

Mechanical Anchor Size (in)

Connection Size (in)

Torque (ft·lb)

9 ⁄8

5

4 ⁄2 IF

5

7 ⁄8

3 ⁄2 IF

7

3 ⁄2 IF

1

30,000

1

15,000

1

15,000

7

6,500

3

4,500

5 ⁄2

1

2 ⁄8 IF

1

2 ⁄8 IF

4 ⁄2

ES20.39754B Operating Instructions

Connection Size (in)

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Trackmaster Whipstocks Wellbore Departure Systems Confidential Property of Smith International North Sea Ltd.

Section 3 3.0

Preparation for Sidetrack 3.1

Equipment

Note: Before running the mechanical anchor, make sure that the foot is larger than the I.D. bore of the bridge plug for proper actuation of the trigger release.

Note:

3.2

3.1.1

Account for and inspect all equipment for possible damage during shipment. Check condition of all connections, fittings and any hydraulic lines on the whipstock assembly.

3.1.2

Caliper and record the O.D. of the mill and the dimensions of the bottom hole assembly components. Measure and record length of whip face.

3.1.3

If the running tool is used, remove the piston. Check the condition of the piston and O-ring. The piston will be reinstalled after the system has been filled with hydraulic fluid.

If running tool has only one end that is bore-backed, then be sure bore-backed end is pointed down (i.e. end that is made-up to the mill). 3.1.4

Check the fit of the orifices (nozzles) in the lead mill nozzle housings. The threads must be clean, free of dings and burrs. Flush the mill if needed to clear obstructions. Use the bottom threads taps if rework is needed.

3.1.5

Check for proper make up of the break-off plug and control line hose adapter to the nozzle housing without the O-rings and remove them before transferring the mill to the drill floor. Also, check for proper make up between the break bolt and the mill.

Well Preparation 3.2.1

Prior to running the equipment make a gage ring and casing scraper run. It is strongly recommended to run the scraper past the setting depth by 30-60 feet, and then pulled back. This is to ensure any debris is pushed below the setting depth and not circulated back up past the scraper.

3.2.2

Make a casing collar locator run. The bottom of the whipstock assembly must be set two to six feet above a casing collar. Review cement bond log if available. This is to ensure optimum milling performance. Record the depth on the job report.

Trackmaster Whipstock 12 of 32 Wellbore Departure Systems Confidential Property of Smith International North Sea Ltd.

ES20.39754B Operating Instructions

Section 3

3.3

Preparation for Sidetrack

Milling Fluid Guidelines 3.3.1

High viscosity “milling mud” is not required when using the Trackmaster Wellbore Departure System for sidetracking. The drilling fluid must be in good condition, clean, and compatible with the formation surrounding the milled window.

3.3.2

Drill pipe filter screens and suction pit screens should be used to remove all forms of debris. It is a good practice to circulate bottoms up to ensure that all the drilling fluid is in good condition prior to milling. Debris in the wellbore will be taken into the drill pipe through the ports of the NAMCBPV if one is used. Any debris that enters the drill string can potentially cause problems.

3.3.3

Polymer drilling fluids, in good condition, do not require any special adjustments. For water based and oil based drilling fluids, a ratio of plastic viscosity to yield point (PV:YP) as close to 1.0 or less is ideal for steel cuttings removal.

3.3.4

The optimum flow rate is 50-gpm per inch of casing I.D., with the minimum being 30-gpm per inch of casing I.D. Although turbulent flow can remove steel cuttings from the hole faster than laminar flow, it can cause problems such as bird nesting of cuttings and a restrictive build-up of cuttings. Laminar flow provides the best overall properties for removal of steel cuttings. Therefore, laminar flow is preferred over turbulent flow for lifting the cuttings out of the well. In optimum conditions, it is recommended to start with a high laminar flow. Small adjustments can be made in the flow rates, rotary speed, and weight while monitoring the cuttings for size, shape, and thickness.

3.3.5

High viscosity sweeps can be pumped periodically based on the amount of cuttings returned to the surface or at a minimum, pumping a high viscosity sweep with bottoms-up circulation prior to pulling out of the hole at the end of the sidetrack.

3.3.6

Ditch magnets should be placed in the first tank beyond the shale shaker prior to milling to capture cuttings. This will decrease mud pump damage due to cuttings contamination. The magnets should be periodically cleaned. They should stay in for several days after the sidetrack to recover any additional cuttings that were trapped downhole or until no more steel cuttings are collected.

ES20.39754B Operating Instructions

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Trackmaster Whipstocks Wellbore Departure Systems Confidential Property of Smith International North Sea Ltd.

Preparation for Sidetrack

3.4

Section 3

Non-Advancing Multi-cycle Bypass Valve Test Procedure 3.4.1 To surface test the Non-Advancing Multi-cycle Bypass Valve (NAMCBPV) have the following components available.

3.4.2

•

Kelly cock (closed) or test cap

•

NAMCBPV

•

MWD assembly

•

Drill pipe or BHA components (2-3 stands), sufficient to ensure the NAMCBPV is below the rotary table.

Pick up the MWD assembly with sufficient BHA to create a stand to set back later in the derrick.

3.4.3 Lower the stands into the hole and make it up to the kelly or top drive. 3.4.4

Start circulation at a minimum flow rate or until MWD pulse is achieved. Stop circulating. Record the circulation rate and pressure.

3.4.5

Pick up and add the NAMCBPV with the closed kelly cock or test cap to the assembly.

3.4.6

Run the assembly back into the hole.

3.4.7

Start circulation and increase the flow rate to more than the value required to close the valve. MWD pulses must be observed. Stop circulating. Record the circulation rate and pressure. See Table 3 for the flow rates to close the valve.

3.4.8

Repeat the starting and stopping of circulation four more times to cycle the piston and to test the MWD.

3.4.9

Slowly start circulation and stop for the sixth time to test the closing of the valve.

Note: High pressures may be experienced during this step. All personnel must be made aware and all necessary precautions taken. 3.4.10 Repeat to verify that the valve closes again without cycling back to the starting position. Note: If the piston cycles back to the starting position or does not hold pressure, pick up and test the backup valve. 3.4.11 Pick up and break NAMCBPV at top inlet crossover (top sub) connection. Safety Note: Take care when pumping against a closed Non Advancing Multi-Cycle By-Pass Valve. Trackmaster Whipstocks 14 of 32 Wellbore Departure Systems Confidential Property of Smith International North Sea Ltd

ES20.39754B Operating Instructions

Section 3

Preparation for Sidetrack

Table 3 Flow Rate to Close Non Advancing Multi-Cycle By-Pass Valve Mud Weight (lb/gal)

(GPM) – 5" NAMCBPV 0.875" Nozzle

(GPM) – 6-3/4" NAMCBPV 1.375" Nozzle

242 226 215 206 198 191 184 179 173

525 489 467 447 429 414 399 387 375

8.7 10 11 12 13 14 15 16 17

ES20.39754B Operating Instructions

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Trackmaster Whipstocks Wellbore Departure Systems Confidential Property of Smith International North Sea Ltd.

Section 4 4.0

Trackmaster Whipstock System Make up Procedure 4.1

The bottom hole assembly will consist of: •

Trackmaster Whipstock Assembly

•

Trackmaster Mill

•

Trackmaster Running Tool

•

One Joint HWDP (Flex Joint)

•

Non Advancing Multi-Cycle By-Pass Valve or Hi-Flow Bypass Valve

•

MWD tool

•

HWDP

•

Drill pipe to surface

Note: The NAMCBPV should be tested prior to being run in hole. It is recommended to be shipped to the rig “ready to use”. It should be left ready to function on the first or second cycle. If a test at the rig is required, see NAMCBPV Test Procedure in Section 3.4. Note: The anchor and hinge connector sub should be attached and pre-torqued at the Smith Services facility. Note: The running tool is not used in the assembly when using a whipstock assembly with the mechanical set anchor. 4.2

Pick up the whipstock assembly from the catwalk with a crane and a winch. A certified lifting eye is provided at the back of the whip. Remove the anchor protector on the rig floor.

4.3

Make sure to sling around the anchor body and not around the slips.

4.4

Check the quantity of running, setting, and shear screws fitted.

4.5

Run the assembly below the rotary table to the top of the whip.

4.6

With the sling still attached to the back of the whip, secure the assembly by passing the false rotary table pin through the whip hook retrieval slot as shown in Section 7. If a hook slot is not available, use slips and a safety clamp.

4.7

Pick up the Trackmaster Mill and running tool on a lifting sub. Slowly lower the mill to the top of the whip face.

Note: The Trackmaster Mill and running tool should be pre-torqued at the Smith Trackmaster Whipstock 16 of 32 Wellbore Departure Systems Confidential Property of Smith International North Sea Ltd

ES20.39754B Operating Instructions

Section 4

Trackmaster Make up Procedure

Services facility. If mill and running tool are made-up on the rig, ensure connection is torqued properly. 4.8

Install rubber grommet into mill. Thread locking pin into mill until tip is flush with counterbore. Align and stab mill onto break bolt. Caution: Ensure tip of locking pin is seated in groove of break bolt. See Figure 2. Tighten locking pin into the mill.

Note: If using a mechanical anchor, proceed to Step 4.12. 4.9

Remove the blanking cap from the lead mill. Use Teflon tape on the threads, attach and tighten the control line assembly to the control line hose adapter.

4.10

Pick up the weight of the assembly. Remove the false rotary table (if one is used). Set the slips and the safety clamp on the running tool, break out the lift sub, remove the floating piston and fill with clean hydraulic fluid to within one foot of the top. Allow 15 minutes for the entrapped air to be released.

4.11

Install the floating piston in the running tool. Fit blank cap.

Note: When using heavily weighted drilling fluid, such as hematite, that has the potential of gelling over or bridging drill pipe, pack the top of the running tool, from the piston to the top of the box with grease. 4.12

Pick up a single joint of Hevi-Wate or high grade, fully inspected, drill pipe with the elevators. Make up the connection.

Note: The flex joint should be of high-grade steel (Grade G-105) or Hevi-Wate and thoroughly inspected at both the connections and the tube before use. Change out to a different flex joint after each mill run. 4.13

Lower and set the assembly in the rotary table. Make up the Non Advancing MultiCycle By-Pass Valve to the Hevi-Wate drill pipe. A crossover sub may be required.

Note: If orientation of the whipstock assembly is not required, proceed to Step 5.1.1. 4.14

Pick up MWD. Make up connection to the Non Advancing Multi-Cycle By-Pass Valve. Crossover subs may be required.

4.15

Align the MWD to the whip face by scribing a line from the center of the whip face up the assembly to the MWD collar and orientation sub. Orient the key in orientation sub to the scribed line.

Note: When using a Gyroscope, replace the NAMCBPV and MWD with a universal bottom hole orienting sub (UBHO). Note: The company representative and directional driller must check the scribe-line and witness the input of any off set data into the MWD computer. ES20.39754B Operating Instructions

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Section 5 5.0

Running Procedure 5.1

Run the Whipstock Assembly 5.1.1

Make up the remainder of the BHA. Pick up drill collars and/or HeviWate drill pipe equivalent to: 1) The recommended milling weight plus a minimum of 25% additional when using a Trackmaster Hydraulic Anchor or 2) The set down load when using a Trackmaster Mechanical Anchor.

Note: No jars should be run with this assembly. 5.1.2

Trip into the hole slowly with the hook on the block in the unlocked position. Monitor weight indicator for hole drag and trip tank for proper fill up.

Caution: Use caution while tripping the whipstock assembly into or out of the hole. Sudden starts, stops, or dropping of the drill string may damage the break bolt. Extra caution should be observed when passing through the BOP’s and wellhead. Note: For a whipstock assembly with a mechanical anchor, trip within 50 feet of the bridge plug. Care should be taken not to run into the bridge plug and cause the anchor to set. 5.1.3 5.2

When the desired depth is reached, work the string up and down to determine hole drag. Slack off to a neutral weight. Correlate on depth.

Orient the Whipstock Assembly 5.2.1

Two methods of orientation are available, Gyro or MWD. Gyro orientation is achieved by installing an UBHO in the BHA just above the whipstock running tool. When on depth, wire line must be rigged up and run in the hole to confirm orientation before pressuring up the drill string in a controlled manner. MWD orientation is achieved with the use of a Non Advancing Multi-Cycle By-Pass Valve. The valve provides circulation to allow tool face surveys to be recorded. The valve is configured to cycle five times before closing at the sixth cycle, which will allow for any potential MWD problems.

Trackmaster Whipstock 18 of 32 Wellbore Departure Systems Confidential Property of Smith International North Sea Ltd

ES20.39754B Operating Instructions

Section 5

Running Procedure

Note: If orientation of the whipstock assembly is not required, proceed to Step 5.3. 5.2.2 Survey the orientation of the whipstock assembly. Turn the assembly to the required tool face and repeat as needed. Caution: 5.3

Make sure that the NAMCBPV does not close during orientation. This will cause hydraulic set anchors to prematurely set.

Set the Whipstock Assembly 5.3.1 Trackmaster Hydraulic Anchor Caution:

High pressure may be experienced during the setting procedure. All personnel must be made aware and all necessary precautions taken.

5.3.1.1 Once properly oriented, verify that the assembly is at the setting depth. Place a reference mark on the Kelly (or drill pipe). 5.3.1.2 Circulate as needed to close the Non Advancing Multi-Cycle ByPass Valve. Set the anchor slips to the casing I.D. by gradually applying 3,000 to 3,500-psi pressure through the drill string and hold. MONITOR THE PRESSURE. 5.3.2 Trackmaster Expandable Anchor 5.3.2.1 Once properly oriented, verify that the assembly is at the setting depth. Place a reference mark on the Kelly (or drill pipe). 5.3.2.2 Circulate as needed to close the Non Advancing Multi-Cycle ByPass Valve. Set the anchor slips to the casing I.D. by gradually applying 3,000 to 3,500-psi pressure through the drill string and hold. MONITOR THE PRESSURE. 5.3.3 Trackmaster Mechanical Anchor Note: The Trackmaster Mechanical Anchor relies on weight to be set. Avoid running it in high angle holes. 5.3.3.1 Once properly oriented, set the anchor by lowering the assembly to contact the bridge plug with approximately 3,600 lb of force. This force is required to shear the plunger rod shear screw on the bottom of the anchor. This will release the setting spring and move the slips to the casing I.D. 5.3.3.2 Mark the pipe. Pick up at least one foot. All setting weight applied to the anchor should be held by the anchor. The anchor should not return to the bridge plug.

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Running Procedure

5.4

Section 5

Break the Mill from the Whip 5.4.1 Trackmaster Hydraulic Anchor 5.4.1.1 On all sizes, pull and slack off three to five times at approximately one-half (1⁄2) the break bolt shear value (Table 4), while maintaining 3,000 to 3,500-psi. Hold each strain for one minute. Finally, pull until the break bolt parts. Monitor for a pressure drop as the break bolt parts breaking the control line hose. Table 4 Approximate Break Bolt Shear Values (Standard) Whipstock Assembly Size (in)

Break Bolt Shear Values (lb)

3

75,000

3

75,000

3

55,000

5

55,000

13 ⁄8 11 ⁄4 10 ⁄4 9 ⁄8 5

7 ⁄8

40,000

7

35,000

5 ⁄2

1

20,000

1

15,000

4 ⁄2

5.4.2 Trackmaster Expandable Anchor 5.4.2.1 On all sizes, pull and slack off three to five times at approximately one-half (1⁄2) the break bolt shear value (Table 5), while maintaining 3,000 to 3,500-psi. Hold each strain for one minute. Finally, pull until the break bolt parts. Monitor for a pressure drop as the break bolt parts breaking the control line hose. Table 5 Approximate Break Bolt Shear Values (Standard) Whipstock Assembly Size (in)

Break Bolt Shear Values (lb)

3

13 ⁄8 x 20 5

75,000 3

55,000

7 x 9 ⁄8

35,000

9 ⁄8 x 13 ⁄8 5

5.4.3 Trackmaster Mechanical Anchor 5.4.3.1 Apply the set down load noted in Table 6 to shear the break bolt. Continue applying load to the recommended set down load to enhance the set of the slips. 5.4.3.2 Pick up to neutral string weight and then apply the set down load a second time.

Trackmaster Whipstocks 20 of 32 Wellbore Departure Systems Confidential Property of Smith International North Sea Ltd

ES20.39754B Operating Instructions

Section 5

Running Procedure

Table 6 Set Down Loads and Approximate Break Bolt Shear Value (Standard) Set Down Load (lb)

Break Bolt Shear Value (lb)

9 ⁄8

5

65,000

55,000

7 ⁄8

5

50,000

40,000

7

50,000

35,000

5 ⁄2

1

30,000

20,000

1

25,000

15,000

Whipstock Assembly Size (in)

4 ⁄2

5.5

Mill the Window 5.5.1

Position the mill two to three feet above the top of the whip. Record pick up weight, slack off weight, rotating string weight, rotary speed, torque, circulation rate and pressure.

5.5.2

Slowly lower the mill until it contacts the whip. Monitor for a pressure drop as the break-off plugs break during the initial contact with the whip and casing if the system is pressurized.

5.5.3

A light amount of weight, 2,000 lb, should be used during the initial milling. Continue milling according to the recommended milling parameters as shown on Table 7. Use the reference mark to indicate when to expect torquing. Table 7 Recommended Milling Parameters Casing Size (in)

Weight On Mill (klb)

Mill rpm

3

2 – 20

60 – 120

3

2 – 17

60 – 120

3

2 – 15

60 – 120

9 ⁄8

5

2 – 15

60 – 120

5

2 – 12

60 – 120

13 ⁄8 11 ⁄4 10 ⁄4 7 ⁄8 7

2 – 12

60 – 120

5 ⁄2

1

2– 7

60 – 120

1

1– 7

60 – 120

4 ⁄2

Note: When the center point is reached, a decrease in torque and/or penetration may be experienced. Should this occur, increase the weight on the mill and decrease revolutions per minutes (rpm). This will cause the mill to flex away from the face of the whip and off the center point. When the center is passed, an increase in penetration and torque will be recognized. After one foot of penetration at the increased weight, bring the milling weight and rpm back to that previously used and continue milling the window.

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Running Procedure

Section 5

Note: The quality of annular job cement and formation type can affect the required rpm and weight needed to mill the window. 5.5.4

If the penetration rate falls below what is expected for the amount of time spent milling, pull out of the hole. Replace the mill and continue milling.

Note: Change out to a different high grade, fully inspected, drill pipe after each mill run. 5.6

5.7

5.8

Drill the Rathole 5.6.1

Make several reaming passes through the window and back to bottom to clean up any burrs. Check against possible fill.

5.6.2

After reaming, stop rotating and slack off through the window. If unusual drag is encountered, ream until smooth. This facilitates the running of other assemblies through the window during future operations.

Pull Out of the Hole 5.7.1

Circulate bottoms-up and pull out the hole.

5.7.2

Inspect and record the condition, wear patterns and gage of the milling segments on the mill to verify that the window’s condition is acceptable.

Drilling Recommendations 5.8.1

Make up the desired drilling assembly and continue normal drilling operations.

5.8.2

It is recommended that a bit or stabilizer not be rotated down the face of the whip. Doing so may damage the edge or catch on the whip.

5.8.3

Leave the hook unlocked on all trips out of the hole. Pass through the window very slowly on all trips.

Trackmaster Whipstocks 22 of 32 Wellbore Departure Systems Confidential Property of Smith International North Sea Ltd

ES20.39754B Operating Instructions

Section 6 6.0

Retrieving the Whipstock Assembly The engineering specifications for retrieving the whipstock assembly can be found on Table 8 and Table 9. Table 8 Whipstock Assembly Retrieving Specifications with Hydraulic Set Anchor or Mechanical Set Anchor Whipstock Assembly Size (in)

Hydraulic Anchor Sub-assembly Maximum Torque Overpull (ft·lb) (lb)

Mechanical Anchor Hook Sub-assembly Retrieval Maximum Tool Torque Overpull MaximumLo (ft·lb) (lb) ad (klb)

3

30,000

114,000

-

-

-

3

30,000

95,000

-

-

-

3

30,000

95,000

-

-

-

5

9 ⁄8

20,000

95,000

15,000

36,000

170 (bored)

5

14,000

65,000

15,000

27,000

-

13 ⁄8 11 ⁄4 10 ⁄4

7 ⁄8

11,000

65,000

15,000

27,000

120/150 bored/solid

5 ⁄2

1

4,000

45,000

6,500

18,000

100 (bored)

1

4,000

28,000

4,500

12,000

44 (bored)

7

4 ⁄2

Table 9 Whipstock Assembly Retrieving Specifications with Expandable Anchor Whipstock Assembly Size (in) 3

13 ⁄8 x 20 5

3

9 ⁄8 x 13 ⁄8 5

7 x 9 ⁄8

ES20.39754B Operating Instructions

Expandable Anchor Maximum

Hook Retrieval Tool Maximum Load (klb)

Torque (ft·lb)

Overpull (lb)

50,000

114,000

–

30,000

95,000

170 (bored)

20,000

65,000

120/150 bored/solid

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Retrieving the Whipstock Assembly

6.1

6.2

Section 6

Hook Assembly Retrieval Tool 6.1.1

A whipstock assembly with a hook slot in the whip face can be retrieved with the Hook Assembly Retrieval Tool. The tool is designed to be hooked into the slot in the whip and then pulled to release the assembly.

6.1.2

A typical BHA for retrieval is: retrieval tool, full gage stabilizer, joint of drill pipe, surveying equipment, crossover, heavyweight drill pipe and drill pipe.

6.1.3

Make up the hook assembly retrieval tool. Orient the reverse side of the hook tang to the orienting sub. Note the orientation and placement of the nozzle in the tool.

6.1.4

Lower the retrieving tool to just above the whip and record operational parameters such as free rotating torque and rotating string weight. Orient and jet wash the hook slot in the whip.

6.1.5

Position the hook tang below the slot on the whip face after completing the washing operation.

6.1.6

Slowly work the string up and down the whip face to drop the hook tang into the slot. Be prepared to work the string with minor alterations in the hook tang attitude to engage the slot. Set down against the bottom of the slot to confirm engagement. Slowly apply right-hand torque. If hook is engaged, the string will torque up thus further confirming hook engagement.

6.1.7

Once engaged, pick up and apply overpull to release the assembly. Increase the overpull to compensate for drag if necessary. If release is not achieved at the anchor overpull load listed in Table 8 or Table 9, increase the overpull in stages up to maximum load for the hook, also listed in same tables. Do not exceed this load. Note maximum hinge pin shear load in Table 10. Do not exceed this load.

6.1.8

If it is not possible to recover the whipstock assembly without exceeding the hook assembly retrieval tool maximum load, release and recover the tool by rotating out of the slot. Pull out of the hole and proceed with the die collar assembly retrieval tool as detailed in Section 6.2.

6.1.9

Upon release of the whipstock assembly, pick up and observe the well for fluid loss and check for flow. Then pull out of the hole. Avoid surging or swabbing the well while tripping.

Die Collar Assembly Retrieval Tool 6.2.1

A whipstock assembly can be retrieved using a tool that has a die collar (box tap) section designed to pull the whipstock and a cut lip guide to lift the whip off the casing wall.

Trackmaster Whipstocks 24 of 32 Wellbore Departure Systems Confidential Property of Smith International North Sea Ltd

ES20.39754B Operating Instructions

Section 6

Retrieving the Whipstock Assembly

6.2.2

Note:

Verify that the correct cut lip guide on the die collar assembly is correct for the weight of casing. A typical BHA for retrieval is: retrieval tool, full gage stabilizer, bumper sub, fishing jar, full gage stabilizer, crossover, heavyweight drill pipe and drill pipe. A safety joint and accelerator jars are used in some assemblies.

Ensure the cut lip guide is not too long so as to prevent engagement. 6.2.3

Lower the retrieving tool to just above the whip and record operational parameters. Start slow right hand rotation (20 rpm) of the drill string above the whip and continue slacking off the drill string until torque and weight indications show whip engagement. Weight should close the bumper sub when at the top of the whip. Apply only minimal weight on the whip.

6.2.4

Work torque down the drill string to fully engage the whip. Exceeding the torque values listed in Table 8 and Table 9 may damage the anchor.

6.2.5

Apply overpull to the anchor to release it. Bleed down the jars prior to pulling. A low jarring load may be necessary should it not release at the over pull value. See Table 8 and Table 9 for the anchor and setting tool release values.

6.2.6

Upon release of the whipstock assembly, pick up and observe the well for fluid loss and check for flow. Then pull out of the hole. Avoid surging or swabbing the well while tripping.

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Retrieving the Whipstock Assembly

6.3

Section 6

Sheared Hinge Pin Should the hinge pin shear while working to retrieve the whipstock assembly, a standard overshot can be used on the hinge connector fishing neck to recover the remaining assembly. See Table 10. Table 10 Shear Values for the Hinge Pins and Fishing Neck Dimensions Hydraulic Anchor Sub-assembly Size (in)

Hinge Pin Shear Values (lb)

Fishing Neck (in) Diameter Length

3

200,000

10.125

3

140,000

6.625

20.000

3

140,000

6.625

20.000

9 ⁄8

5

150,000

6.625

20.000

7 ⁄8

5

150,000

5.000

20.000

7

13 ⁄8 11 ⁄4 10 ⁄4

20.000

150,000

4.750

20.000

1

5 ⁄2

100,000

3.640

15.000

4 ⁄2

1

42,500

2.875

14.625

Expandable Anchor Sub-assembly Size (in)

Hinge Pin Shear Values (lb)

3

13 ⁄8 x 20

Fishing Neck (in) Diameter Length

200,000

10.125

20.000

3

150,000

6.625

20.000

7 x 9 ⁄8

150,000

4.750

20.000

5

9 ⁄8 x 13 ⁄8 5

Mechanical Anchor Sub-assembly Size (in)

Hinge Pin Shear Values (lb)

Fishing Neck (in) Diameter Length

9 ⁄8

5

150,000

6.625

19.500

7 ⁄8

5

150,000

4.750

20.000

7

150,000

4.750

20.000

5 ⁄2

1

100,000

3.640

15.000

1

42,500

2.875

14.750

4 ⁄2

Trackmaster Whipstocks 26 of 32 Wellbore Departure Systems Confidential Property of Smith International North Sea Ltd

ES20.39754B Operating Instructions

Section 7 7.0

Best Make up Practices for the Trackmaster Whipstock Assembly Step 1 Tool to hold the whipstock in the rotary. Note the T-Bar.

Step 2 Slot in whip for the T-bar.

Step 3 Protector on mill.

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Best Make up Practices of the Trackmaster Whipstock Assembly

Section 7

Step 4 Pulling mill through V-door. Note: To avoid possible damage do not impact mill against anything.

Step 5 Removing protector from the mill.

Step 6 Moving whipstock assembly through V-door.

Step 7 Removing protector from the anchor. Note: Sling around the protector.

Trackmaster Whipstocks 28 of 32 Wellbore Departure Systems Confidential Property of Smith International North Sea Ltd

ES20.39754B Operating Instructions

Section 7

Best Make up Practices of the Trackmaster Whipstock Assembly

Step 8 Protector removed from the anchor.

Step 9 Lowering the whipstock assembly into well.

Step 10 Whipstock assembly in false rotary.

Step 11 Removing sling from whip.

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Best Make up Practices of the Trackmaster Whipstock Assembly

Section 7

Step 12 Bolt in place in whip to receive mill.

Step 13 Mill aligned with whip.

Step 14 Mark on draw works to highlight small movement required.

Step 15 Attaching mill to whip.

Mark

Trackmaster Whipstocks 30 of 32 Wellbore Departure Systems Confidential Property of Smith International North Sea Ltd

ES20.39754B Operating Instructions

Section 7

Best Make up Practices of the Trackmaster Whipstock Assembly

Step 16 Mill and whip aligned.

Step 17 Removing the lifting hook from the whip.

Step 18 Fitting hydraulic hose.

Step 19 Attaching hydraulic hose to mill.

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Best Make up Practices of the Trackmaster Whipstock Assembly

Step 20 Whip and mill attached.

Section 7

Step 21 Tightening lower fitting of hydraulic hose.

Step 22 Whipstock assembly ready for alignment with MWD.

Trackmaster Whipstocks 32 of 32 Wellbore Departure Systems Confidential Property of Smith International North Sea Ltd

ES20.39754B Operating Instructions