Volume 1, No. 1

	Coiled Tubing Solutions Handbook offers a concise selection of products, services and solutions for numerous applications.

Baker Oil Tools is proud to announce the release of the Coiled Tubing Solutions Handbook. This handbook is a collaboration that includes products and services from the Workover Systems, Fishing Services, Sand Control, Flow Control, and Open Hole Completions product lines.

The handbook offers an unparalleled selection of coiled-tubing-conveyed intervention products, services and solutions with which to approach individual well requirements. For that reason, Baker Oil Tools has designed the handbook to highlight system capabilities within eight distinct intervention areas where coiled tubing can offer a highly effective and cost-efficient alternative. These eight categories are: Well Cleaning, Fishing and Milling, Zone Isolation, Stimulation and Fracturing, Sand Control Completions, Flow Management, Plug and Abandonment, and Sidetracking and Re-entry.

The Coiled Tubing Solutions Handbook can be downloaded in PDF format electronically or a hard copy spiral-bound handbook and can be ordered by contacting Marketing Services.

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	Baker Oil Tools and Hughes Christensen combined design and engineering talents to create the PathMAKER Formation Mill; designed to mill a full gauge window and rat hole in a variety of hard and abrasive formations. The collaboration pays off in a dual-use application in the Dinwoody formation.

The PathMAKER^™ Formation Mill is the result of an ongoing development program in conjunction with Hughes Christensen’s Genesis^™ technology. It’s proved successful in a recent application in which an operator needed a window cut in 7-in. 32 lb/ft casing at 11,682 feet to perform sidetracking operations. The Dinwoody formation in this area is known to be extremely difficult drilling. It is made up of dolomite sandstone with a compressive strength of 25-30 KPSI that is normally drilled with an IADC code 617 insert type roller cone bit. This formation has typically taken as many as three trips to perform a casing exit with standard window mills. Previously, the added cost of extra materials and rig time made sidetracking a less economical choice.

The PathMAKER Formation Mill was run in hole on the WindowMaster G2^® Whipstock System and set in place on a TorqueMaster™ Bottom Trip Anchor.  A 12-foot window was cut in the casing, in addition to the 10 feet of open hole as required by the customer.  Complete time for window milling and drilling on this job was only 7 hours; significantly less than previous exits cut with Tungsten Carbide mills. The window cutting operations were completed in one day, saving the customer two days of rig time - when compared to previous operations. Upon inspection, only 1/16-in. gauge wear was observed with 95% of the PDC cutters undamaged. 

In subsequent drilling operations the lateral wellbore had to be plugged and abandoned.  A new window was required.  Baker Oil Tools was called in to repeat their successful window cutting operation above the original kick-off point.  The same PathMAKER Formation Mill was run in-hole as was used in the previous operation.  A 12-foot window and 5-foot rat hole were successfully milled in only 10 hours.  The PathMAKER Formation Mill suffered little extra wear after milling the second window.  Final gauge loss was still only 1/16-in. 

The proven performance and robustness of the PathMAKER Formation Mill makes it a vital part of the extensive Fishing Services product offering.

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	The Baker deepwater plug and abandonment (P&A) system is, once again, successfully run for a customer in the Gulf of Mexico; saving them a considerable amount of rig time.

The customized system enabled the customer to save a trip by not having to pull the casing hanger seals and the casing in separate trips. A Marine Swivel Seal Extractor was made-up, along with a Multi-String Casing Cutter and Hydraulic Casing Spear. The swivel was landed and an overpull taken to verify the seal had latched. Once the overpull was released, the cutting operations started.

The 13-5/8 in. Q125 casing was cut in 20 minutes and the lower annular closed. The hanger seals were then pulled and the pressure of the well checked. Slight pressure was noted and the well was then killed. The string was pulled to position the Hydraulic Spear just below the hanger, the spear was set and casing was pulled. 

Because the fishing team is able to cut the casing with the hanger seals locked-in before cutting, greatly reduces damages to the subsea wellhead. The Tension Cut & Pull Subsea Wellhead Retrieving System proves to be Best-In-Class because of its ability to pull the casing without having to perform a very hazardous stripping-out process at the surface. 

The Universal Wellhead Retrieving System was then made up and run in-hole to cut 20–in. and 36–in. casing strings and recover the wellhead in one trip. An overpull of 50,000 lbs was recorded and the casing strings were cut in just over 4 hours; recovering the wellhead.            

Features and Benefits of the P&A System by Baker Oil Tools:

• The ability to cut casing strings in tension

• System does not require the use of motors - which may affect the casing cutter

• System does not need special dogs for different wellhead manufactures’ wellheads. It will fit all wellheads.

• Most of the older tools either cut the casing strings in compression or only allowed for a slight overpull. This system allows the operator to pull as much as 300,000 lbs over the work string weight. This not only provides a quicker cut but allows for instance indications when the casing strings are cut.

• The Multi-String Casing Cutters have also been improved by adding strength to the knives and using the proven METAL MUNCHER^® cutting technology.

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	The Rocky Mountains region, thru-tubing fishing team continues to set new records in the removal of stimulation and fracturing plugs.

At the same time, the team repeatedly demonstrates value-added coiled tubing solutions to new and existing clients in that area. 

The team’s latest success involved the difficult task of milling in a high pressure gas well [completed with 4-1/2 in. 13.5 lb/ft casing, flowing THP was 6,000psi] to remove a total of sixteen tools; four, Generation 2.0 bridge plugs and twelve Hi-Value frac plugs. 

The milling assembly, comprised of standard running tools, a 2-7/8 in. OD Navi-Drill^® VIP™ workover motor and 3-3/4 in. OD Bo-mill, dressed with unique Opti-cut™ cutting inserts. The assembly was deployed on 1-3/4 in. OD coiled tubing, with an available flow rate of 2 BPM. Straight water was used as the primary power fluid, with 10 Bbl sweeps of gel pumped occasionally. The well began flowing at 8MMCf/day to assist cuttings removal.

The average millout time per plug was approximately 40 minutes and all sixteen plugs were successfully removed with the same, single milling assembly. The systems approach delivered to the customer, high performance and efficiency at a significantly reduced cost.

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	A major exploration company operating in the Gulf of Mexico recently needed to cut 4–in. 14# S135 drill pipe. Flow rate available, restrictive ID’s and depth of work made the operation a challenge from the beginning.

The fishing services group was asked to develop a method to locate, anchor and cut drill pipe with only 30 gallons per minute of flow available.

Challenge 1 – locating and anchoring technique

Choosing a locating and anchoring technique was the first hurdle the team encountered. Because the Hydraulic/Mechanical Tubing uses an indiscriminate anchoring mode, it will anchor in any ID that it can pass through and then expand outward until the collect overruns the cone and will not extend any further. The drill pipe had a tube ID of 3.340–in. and a joint ID of 2.563–in. The goal was to enable the anchor to pass through the tube ID when fully expanded, but locate and set in the joint ID. A stop device was engineered and manufactured to prevent the collet from expanding beyond than 2.75-in. The anchor was then tested in a joint of drill pipe the exploration company supplied for the expressed purpose of these tests. A flow rate of 15 gallons per minute and 150 PSI was required to activate the anchor. The stop device would not allow the anchor to set in the tubing ID but did allow the collet to locate and set in the joint ID. A set-down force of 5,000 pounds was applied to the anchor without deformation of the components.

Challenge 2 – Cutting drill pipe

The next step was to cut the drill pipe. Coiled tubing was the chosen conveyance method to cut the drill pipe; which required the use of a mud motor as power to turn the cutter. BOT’s fishing team selected the X-treme^® motor for its ability to produce high torque even at low flow rates. The chosen cutter was a modified DB Underreamer. A bull nose replaced the bottom plate mill to help the cutter to pass through any encountered restriction. The knives were designed to accept high tool pressure created by the DB Underreamer as well as provide good cut indication after removal.

Testing

The DB Underreamer, motor and anchor were tested under the same conditions expected on the job. The tool string was placed inside of the test joint and flow was initiated at 15 gallons per minute. The anchor moved up and down freely in the tube ID but stopped at the joint ID. Flow was stopped, the anchor was located in the joint ID, and flow was started again. The anchor expanded and 3,000 pounds of weight was slacked-off on the anchor. Flow was increased to 30 gallons per minute and the cutter began to cut the pipe. The pipe was completely severed after only five and a half minutes of pumping.

The operator required two consecutive cuts with out making any modification to the tool string. The second cut was made under the same conditions as the first and was completed successfully.

Quick execution of engineering, marketing, manufacturing, and testing earned the fishing team congratulations from the operator on this successful project.

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