PRS PACKER RETRIEVER SPEAR INSTRUCTION MANUAL Manual No. 5-10 FOR: Company Serial No. A Subsidiary of Wilson Industries, Inc. P.0. Box $67, 1710 Burnett Street, Houston, Texas 77001 (713) 287-3060 Telex 76-2675, TOTABLE OF “ CONTENTS GENERAL DESORPTION, (5660005. 0seneeessceaseesavs OPERATIONAL PROCEDURES. TOOL SIZING..... HOLE PREPERATION TOOL SELECTION. . TOOL MAKE-UP. ... MAKE-UP TORQUE TABLES RUNNING PROCEDURES. FIELD MAINTENANCE. :.. SHOP MAINTENANCE? asset elcee.cis cs eccsnae es caewies ee ENGINEERING DIMENSIONS.....2......000000005 PARTS LIST. UPRERNNPRS MILLING TOOLS GENERAL DESCRIPTION H-E Packer Milling Tools are designed to remove standard full bore production packers from oil well production strings. This removal method con- BUMPER sists of a combination of several tools as illus- JAR trated in Figure 1, which will utilize a cutting mill to cut the packer slips loose and then re- cover the remanent packer parts and leave the casing I.D. smoothe and undamaged.From bottom to top,in Fig.1,a PRS series Packer Spear is as- sembled with the proper size slip to engage the bottom end of specific bore production packers poot and made up on the lower end of sufficiently long BASKET “extension subs to place the spear completely be- low the packer during milling operations.A proper Pen diameter Packer Mill is assembled on a mill body MILL and connected to the extensions. The mill may be either short or long to mill away specific portions of the packer slips and packer. A Boot Basket is EXTENSION generally recommended as a catch sub for the fine hard steel and mill cutting elements which will be loose inthe hole. A Bumper Sub of proper diameter is generally used above the assembly to facilitate pyyen operations of the tools during the operational pro-, SPEAR cedures of packer removal. AL [ FIG. 1PRS MILLING TOOLS OPERATIONAL PROCEDURES ww TOOL SIZING - PRS Milling Tools must be selected that will be compat- able with casing and packer sizes that will permit proper and safe operations of the milling and retrieving operations. Bumper Sub, Boot Basket and mill shoe sizes must be selected to permit removal of cut- tings as the upper portions of the packer are milled up. Extensions and Packer Spear sizes must be selected that will allow penetration and recovery of the uncut packer elements. Specific,exact spear slip catch sizes are required for each exact size packer bore. There is no ‘range' built into the spear slip catch abilty. Reference should be made to drawing 313190 for proper tool selection with respect to each casing size,weight and packer bore as listed. (\ HOLE PREPARATION - Scrapers or drift tools should be run prior to run- ning the PRS Milling Tools to depth. The casing in which the packer is to be removed should be washed clean to the packer top and a fluid and pump equipment must be selected that will clean the mill shoe and re- move all cuttings from the hole as the packer is milled up. The Boot Basket may catch some of the particles,but the most part must be re- moved by the pump fluid.Exact casing bores,packer bores and setting depths must be known as well as exact dimensions of the packer,slip lengths ,upper sleeve or receptacle lenght and/or tail pipe dimensions and length. Proper shoe,spear and extension subs can be selected on the basis of valid packer dimensions.OPERATIOAL PROCEDURES “toon SELECTION - After selecting the proper size spear and the ex- tension subs based upon the packer dimensions,a short mill shoe may be selected to mill away all the packer passed the upper slips. The short shoe is generally selected when the packer is extra large bore and the upper slips are located very near the top of the packer. If there is a long upper receptacle,hold down slips or consider- able distance from the top of the packer to the upper slips on small bore packers it may be advisable to use a long shoe to mill away only the upper portions of the packer until the upper slips have been milled away. Sufficient extensions must be used to place the packer spear completely below the packer where the mill shoe has con- tacted the upper parts of the packer. Boot Basket iand Bumper Subs are selected compatable with the casing size. Enough difference in tool & D. to casing I.D. must be maintained for proper cutting removal and tool running clearance.Generally one half inch annulus is considered minimum clearance for fluid passage and cutting removal except on ex- tremely small sizes where one quarter inch annulus should be maintained. The cutting diameter of the shoe should be one eighth inch smaller than the drift diameter of the casing in which the packer is set.OPERATIONAL PROCEDURES we ‘TOOL MAKE-UP- Packer Spear and extension connections must be made up to the minimum torque values as shown in Table 1 in order to prevent unscrewing of the threads during the milling operations. Frequently the milling operation is not smooth but irregular with respect to torque and — there may be frequent hang-up,releasé and sudden stopping of the mill shoe and lower end of the milling assembly. This in turn sets up large magnitudes of inertial torque which can break and unscrew connections below the mill shoe. Consequently,,use of make - up torques listed below will help prevent premature back-off of exten- sions and spears. PRS MILLING TOOL MAKE —UP ASSY. BUMPER SUB BOOT BASKET | PACKER MILL EXTENSION & NO._|INT. PARTS | EXT. PARTS |SKIRT [TOOL YTS.|SHOE _|FF MILL SPEAR 15027 |.1090. FT-LB| 1000 FT-LH 900FT-LBOOOFT-LA 900FT-LB|900FT-LR 600 FT-LB (Qjs028 | 4500 _"' | 6000_" | 6000" | 6000 " 2000" _|3000 "_|1500__" 15030 | 5000_""_| 9000 " | 8000" | 6000" boo" _|3000 " |2500__" Iasest oan " [20000 "| 8000 "_| 7000 "000 "_|4000 "_[3500__" 15034 [30000 __"_|10000_" | 9000 " | 8000 " [5000 " _|6000 "4000 _"" TABLE 1 When milling up alloy steel packers it may be required to lock the joints using several standard methods or order the H-E PRSI Milling Tool which is designed with locked joint or integral connections be- low the mill shoe. Common lock type joint compounds may be used on spear and extension connections to prevent inertial spin-off during milling operations. In all conditions,if tool strings are up to the torque levels shown in Table 1,the operator can be confident that the lower spear section will stay together during milling operations. veOPERATIONAL PROCEDURES © r= RUNNING PROCEDURES- Make up the tools as shown in Fig.2 Ease the tools past blow-out preventers or well head ORLLARS equipment without jamming the spear or hanging up on the shoe. Once in the casing,the tools can be run at normal speed. Fluid levels inside and out must be SPER quit monitered with regard to proper well control proced- ures. Packer back-up fluids may be staged out of the oe hole and replaced at desired intervals, pumping through the tools. Ifa mixed weight, casing string is |_| in the well,care must be used in passing levels where Becker t different ID. pipe is connected ,as bevels may not be Provided and shoe hang-ups can be expected. Suffic- (Cent drill collar weight should be used above the tools to provide all the weight needed to dtive the shoe. See ae Table 2 “for approx.wts, required. This will prevent a drilling the packer with undesired amounts of Com- pression in production or light drilling strings. |_| EXTENSION J PACKER SPEAR © oS FIG.2PACKER MILL TABLE wv PACKER AAPPX. DRILL COLLAR WT. REQ"D APPX.TIME REQ'D TO MILL UP UPPER SLIPS FLAT MILL SHOE | THIN MILL SHOE|FLAT MILL SHOE| THIN MILL SHO! Thin wall-Alum | 100-200 Lbs./ | 300 Lbs./sq.in|1 ‘Hr. /inch 1/2 Hr. /inch Magnesium Body sq. inch of of Shoe Face |of Casing 1.D.| of Casing 1.D with heat-treated | Mill Face cast iron slips. Thin Wall-Mild 200-300 Lbs./ | 400 Lbs./sq.in|1 Hr./inch 1/2 Hr. /inch or soft steel sq. in. of of Shoe Face |of Casing I.D.|of Casing 1.D body with heat- | Mill Face treat cast iron slips Thick Wall-Soft | 400-500 Lbs./ | 500 Lbs./sq.in}1-1/2 Hr./ 3/4 Wr. /inch Miceo body with | sq.inch of of Shoe Face |inch of Csg. |of casing 1.D heat-treated cast | Mill Face I.D. iron slips Thick Wall-Alloy | 500-600 Lbs./ | 800 Lbs./sq.in}2 Hr./inch 1 Hr./inch steel body with | sq.inch of of Shoe Face |of Casing I.D.] of Casing 1.D heat-treated Mill. Face cast iron slips * Estimates are for rotary RPM range of 90 to 150 “TABLE 2 - Example: Mill up thick wall alloy steel body w/H.T. alloy slips. Packer in 4.625 I.D, x 5-1/2 Casing. Flat Face Mill : Area 4-1/2 0.D. x 2" 1.D. Mill= 12.859 in?. We. req'd is 12.859 x 500/600 Lbs. /in/ = 6500 to 7700 Lbs. or 8 to 9 3-3/4 x 1-3/4 Drill Collars. Thin Mill Shoe : Area 4-1/2 x 3/4 shoe = 8.95 in. Wt.req'd is 8.95 x 800 = 8050 Lbs. or 9 to 10 3-3/4" 0.D. x 1-3/4" I.D. Drill Collars. Note : Drill time is 2 x 4.625 = approximately 9 hours for flat face shoe or I x 4.625 = 4-1/2 hours for thin mill shoe. Additional drill Collar Wt. must be added to counteract ‘pump off' effect. Pump off = area mill face times expected pump pressure accross Mill Face. Best rule is to run wt. than is needed rather than not enough. 6OPERATIONAL PROCEDURES RUNNING THE TOOLS - The RPM required along with weight and optimum pump “pressure must be determined by actual trial as each packer is being cut by the mill or shoe. Rotary speed, weight and pump pressure must be ad- justed until ‘drill off' is achieved. When this point is estimated and maintained, the approximate time required for cutting up half of the packer can be computed from Table 2. Other factors, such as cement at the packer level,sand or set up wt. material and junk will require additional drilling time and vary from the Table values. The Table val- ues are approximate times required to drill the packer alone under ideal conditions of optimum pump pressure, weight control and rotary RPM that have been found to establish the ‘drill off' condition mentioned above. The RPM and wt. values estimated in the Tables should fall in a range that will permit ‘drill off' to be sufficient to remove the packer within the approximates times listed. \ pump pressure and volume must be sufficient to remove all mill cut- tings and keep the mill cutting face clean. A certain amount of ‘drill off" will be observed which can be estimated by applying the estimated pump pressure accross the mill to the area of the mill face. This force must be counteracted by addition of sufficient drill collar weight a- bove the mill assembly which is in addition to the Table estimated drill collar weight required to mill the packer.OPERATIONAL PROCEDURES APPROACHING THE PACKER - As the packer mill string is lowered to the packer level,pump circulation should be established and the top of the packer :h should be washed clean. If obstructions are en- countered the string should be removed and a stan- dard packer bore mill run to clear the obstructione and determine thru-bore of the packer. The standard packer mill string should be re-run to packer depth with a slip mounted on the packer spear that will catch the diameter of the packer bore mill. The standard packer mill string must never be used to attempt to remove obstructions above the packer. (Cling the packer spear thru the packer bore will destroy the packer spear slips. Good string measurements with a reliable packer depth setting figure will permit the operator to deter- mine the proper position of the packer mill string with respect to the set packer.In any event, the packer spear must clear the packer bore and be in,a free position below the packer before milling or rotation of the string. OBSTRUCTION MILL PACKER BORE. MILL FIGURE 3If there are restrictions below the packer such as perforated nipples, landing subs or tail pipe,extensions must be used to position the packer spear well below these points to an enlarged free position so that the rotation of the string will not foul the packer spear as shown in Fig. 4 . MILLING THE PACKER - After lowering the packer string without rotation,until the packer spear is well below the packer,milling operations may begin until "drill off" conditions are established. Generally, light drill loads should be used to start to enable the shoe or mill to cut the thin bevel upper parts of most packers away until full mill or shoe face contact is established. 4dditional weight may be added to establish optimum conditions.Rotary speeds must be established that are sufficient,with a given weight,to burn orabrade: the carbide particle matrix away to expose the successive new cutting edges of carbide particles. FIG. 4N 4"6" Dow AN. When this condition is established the “mill or shoe will cut almost any metal with maximum efficiency. This condition is different for the different materials out of which most production packers are made, hence the "hunt" method must be employed to establish an acceptable packer drill rate. Close observation for changes in packer drill rate along with depth of penetration mearsurements will indicate where and how much of the packer has been milled up.The best conditions of removal for most makes of full bore production packers is to mill up the upper slips and approx. “Shalt of the packing element before retrieval » FIS. 5 is attempted RELEASING THE PACKER - For any of several reasons, it~may be required 3 RH. TORQUE { REMOVE s to remove'tthe Packer Spear and release the Packer. Release of the Packer Spear is accomplished by taking a firm upward strain on the milling string seating the spear in the packer bore. With slight right hand torque, in the string, slack off 4 to 6 inches at the packer and pick straight up, this will "J" up the spear slip and release the packer. 10This release may be required if the mill shoe does not completely (Lai11 up the upper slips and must be replaced or wrong measurements may allow entrance into the packer prematurely and require removal to put on the kelly and pump at.the surface. After release and/or removal, the Packer.bore may be re-entered and the Packer Spear will re-set automatically to re-engage the packer bore. RETREIVING THE PACKER - After mill-up of the upper packer slips most packers may be removed without losing any of the remaining parts by picking straight up on the mill string and unseating the unmilled portion of the packer and lower slips. Several "bumps" may be used by the bumper sub to aid in lower slip release. With the packer caught on. the packer spear,the whole assembly may be “Stemoved from the hole. 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