In offshore platforms, with high well density, slot recovery technique is an efficient way to target new / un-swept avenues to boost the production levels in a mature field. This leads to utilization of an appreciable length of parent bore which is an advantage to the operators globally in terms of surface facility retention and associated rig time saved. This paper discusses an actual case-study wherein dual casing exit was achieved in an offshore platform well resulting in significant time and cost savings.

For the subject well the subsurface targets were quite far from the mother-bore, resulting in a plan to side-track the well at a shallow depth where double casing existed, i.e. 9-5/8″ × 13-3/8″. The options available were pilot milling and dual exit using whipstock. Unlike multi-casing exits, pilot milling is a time consuming method which requires multiple trips and involves large volume of metal swarf handling at surface. The CBL-VDL verified the presence of cement outside 9 5/8″ casing that further supported the case of dual casing exit operation. Consequently, associated risks were discussed and plans to mitigate the same were put in place.

Single-trip 8-1/2″ whipstock-milling system was used to cut a window suitable for running drilling BHAs, liner, and completion equipment. The 9-5/8″ × 13-3/8″ annulus was monitored during milling and FIT test to check for any pressure communications. For well control scenario, arrangements were made for connecting the annulus to the choke manifold to ensure a closed system and thereby have provision of circulating through choke in case of gas migration in the 9-5/8″ × 13-3/8″ annulus. The window milling operation was done using sea water & intermittent Hi-vis sweeps. The window was milled successfully in a "single trip", thereby saving considerable rig time. No excess drag or held-up was observed and gauge loss on mills when pulled out of the hole was negligible. Well integrity was intact with no pressure communication in the annulus. The job was a successful one that led to finishing the well within the planned time and thereby, led to timely release of the jack up rig before the onset of adverse weather conditions.

Multi-casing exit technology in two or three casing strings opens the multi-level advantages to well intervention techniques especially in situations where the wells are old with limited access due to presence of fish or other restrictions that makes the deeper section of the well non-usable. Such sections can be avoided by sidetracking at a shallow depth and also provides an opportunity to access targets that are quite far from the original mother-bore.

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