High Expansion Wedge Stabilizing Mill Assembly in Casing
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Solution Overview
Problem
Current whipstock systems fail to effectively mill windows in larger casing sizes, such as 7″ casing with a 3-½″ tubing string, due to inadequate anchoring and mill assembly instability, leading to high failure rates and costly cement pilot hole preparations.
Innovation Solution
A high expansion wedge with extendable angular wings that secure the milling assembly to the tray face, preventing slippage and ensuring accurate exit point access, eliminating the need for rig workovers and reducing operational costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional whipstock systems are used in 7" casing with 3-1/2" tubing, then the system can be deployed, but the mill assembly cannot stay on the whipstock tray face and anchoring is inadequate
Solution Approach 1:
The whipstock system transitions from a static structure to a dynamic one with extendable wings that can be deployed after insertion. The wings are initially retracted to allow passage through the tubing, then extended to provide stabilization and anchoring support for the mill assembly, resolving the contradiction between initial deployability and subsequent stability.
Solution Approach 2:
The whipstock is divided into functional segments: the main body, the retractable wings, and the anchoring mechanism. This segmentation allows each component to perform its specific function - the main body provides the core structure, the wings provide adjustable stabilization, and the anchoring mechanism secures the assembly, collectively solving the stability issue without requiring overall system complexity.
2Manufacturing precision
If cement pilot hole preparation is performed to ensure mill contact with casing, then exit accuracy is improved, but non-productive time and operational costs increase significantly
Solution Approach 1:
The extendable wings are deployed in advance before the mill assembly arrives, creating the proper geometric configuration and contact surfaces needed for accurate mill-casing contact. This preliminary action eliminates the need for time-consuming cement pilot hole preparation, as the wings are already positioned to guide the mill assembly directly to the correct exit point.
Solution Approach 2:
The extendable wings act as an intermediary element between the whipstock body and the mill assembly. They provide the necessary geometric mediation to ensure proper contact and alignment, replacing the need for cement-based pilot holes while maintaining exit point accuracy and reducing preparation time.
3Stability of the object's composition
If wings are extended to fill the gap between wedge and casing, then mill assembly stability is improved, but device complexity increases
Solution Approach 1:
The wings are nested within the whipstock body during insertion, similar to nested dolls. This nesting allows the complex wing extension mechanism to be compact during deployment through the tubing, then expanded after positioning to provide the necessary stabilization and anchoring support, resolving the contradiction between initial simplicity and subsequent stability.
Data Source
AI summary
A drilling wedge that has, in addition to a normal connector rod, two wings that extend from the sides of the wedge. These wings are angular members that fill much of the space in the larger casing around the wedge. These wings prevent a milling assembly from sliding past the wedge or from moving off to the side, where an exit through the pipe or casing in the wrong place can occur. Instead, the wings help to keep the milling assembly in the proper position on the tray of the wedge to ensure that the milling assembly reaches the proper exit point in the casing. The wings are retracted when the HEW is deployed through the narrower pipe. Once the HEW is properly positioned, the guide cone is extended and the wings are deployed.