Coiled tubing (CT) is one of the most common and effective methods employed to mill out composite bridge plugs (CBPs) that are used to isolate zones during completion. Typically, the zones are normally pressured or over pressured, i.e., each interval approximately the same pressure. Recently, in a New Zealand field, a plan was set to mill out CBPs that had been set between zones that were tight gas and conventional with as much as 3,780 psi pressure differential between them.

One major challenge relates to the CT CBP milling. While milling the plug that isolates the over-pressured zones, the differential pressure can exert significant forces on the milling assembly, raising the potential for buckling/failure of the CT. To reduce this risk it was decided that a bridge plug with an equalizing path would be used to eliminate the large pressure differential and potential upward forces. Another challenge was the issue of cross flow between the zones after milling was completed, and the potential for well control issues due to some under-pressured zones that could not support a full fluid column, causing loss of hydrostatic pressure.

For the under-pressured zones, nitrogen was used to equalize the pressure across the plugs prior to milling them. To minimize the risk of getting stuck and potential CT failure, the operation was closely monitored and optimized by using a CT real-time downhole communication system. The real-time downhole pressure captured by the system during plug milling provided the firm evidence that equalization had occurred.

This paper reviews the selection of plugs/mills and the milling strategy for safely milling CBPs that have been set across zones with significant differential pressures. The benefits of using a CT real-time downhole communication system is discussed by illustrating the case study of successfully removing 25 CBPs with CT in the three wells within a field.

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