Abstract: Milling systems, tools, and methods include using a mill with secondary attrition system to re-mill cuttings and other debris away from the face of the mill. The secondary attrition system may be located uphole of the mill may be used to stage conditioning and re-sizing of debris. After debris is generated by the mill, the secondary attrition system may re-mill the debris to a finer size before allowing the debris to pass out of the sleeve. The debris may be re-milled by secondary cutting elements while within an annular gap positioned radially between the sleeve and a drive shaft for the mill. The annular gap may have a variable width as a result of a tapered outer surface of the drive shaft and/or a tapered inner surface of the sleeve. The variable width may cause debris to be re-milled into increasingly finer sizes.

Abstract: A departure device couples to a bit using a connector that facilitates release of the bit from the departure device. The connector may be more millable than the departure device and can transmit axial and torque loads between the bit and the departure device. The connector may include a material having lesser strength or hardness than the departure device, and may be millable by the bit. Another example connector may have connection points with the bit, and a movable member of the departure device may a force to the connector and contribute to releasing the connection between the bit and the departure device. A tensile connector between the bit and the movable member may apply a tension force to the movable member, urging the movable member toward an extended position in which the movable member is aligned coherently with a sloped face of the departure device.

Abstract: Methods and tools for cutting a component in a wellbore are include use of a downhole tool that is tripped into a wellbore. The downhole tool includes at least one sensor that determines whether a quality of a cement around casing satisfies a predetermined standard. The casing is cut to remove an axial section of the casing and the at least one sensor determines whether at least a segment of the axial section of the casing remains adhered to the cement after the casing is cut. A casing removal tool can be activated to remove any remaining segments of casing in the axial section. A plug can be formed in the area where the axial segment of the casing was removed. The downhole tool may include a cutting tool with a laser, abrasive jet, or other cutting element shielded from wellbore debris by a fluid stream.

Abstract: A milling tool includes a cutting block in a recess in a tool body. The cutting block is configured to extend radially outward from and retract radially inward toward the tool body. The milling tool further includes a milling blade in a recess or cut-out in the cutting block. The milling blade is configured to extend radially outward from and inwards toward the cutting block. One or more links may couple the milling blade to the tool body to cause the milling blade to move radially relative to the cutting block when the cutting block moves radially relative to the tool body. The milling tool may be used as a dual string section mill to remove any of an inner casing, an outer casing, or cement between the inner and outer casings.

Abstract: Systems, tools, and methods include using a milling assembly with a mill having multiple, different types of cutting element inserts. A gage region of the mill includes a first type of cutting element insert, and a shoulder region of the mill includes a second type of cutting element insert. One cutting element insert may include chip-breaking features, and the other may be a shear or gouging cutting element.

Abstract: A heavy weight drill pipe may include a tube body formed of AISI 1340 alloy steel, and first and second tool joints at respective ends of the tube body, and which are formed of an AISI 41XX series alloy steel. The first and second tool joints may be welded to the tube body at a weld line within a weld region. A Charpy impact toughness at the weld line or surrounding weld region may be least 12 ft-lbs. (16.5 N-m). Yield and tensile strengths at the weld line or weld region may be at least 65 ksi (448.0 MPa) and at least 106 ksi (731.0 MPa), respectively. Material properties at the weld line or weld region may be achieved by heat treating after welding. Heat treating may include austenitizing, quenching, and tempering the weld line and/or the surrounding weld region.

Abstract: Tools and method for automatically controlling torque when making-up and/or breaking-down threaded connections between downhole assets such as drill pipe, drill collars, and BAH components. An iron roughneck may be controlled by, for instance, automatically monitoring and adjusting the fluid pressure of cylinders that ultimately provide the torque to the downhole assets. The torque may further be automatically controlled by automatically identifying the downhole assets and selecting a corresponding torque profile or target torque. Clamping force may also be controlled, and is optionally proportional to the target torque.

Abstract: Milling tools, systems, and assemblies may have an adjustable gauge diameter. An example mill may include a body with tracks thereon. The tracks may slope in an axial direction and may be configured to couple to multiple blades. A locking collar may be positioned on the body and may be movable between multiple locking positions. Each locking position may be axially offset from another. At each locking position, the blades may be located at a different axial position on the body. Where the tracks slope, each different axial positions of the blades may also correspond to a different radial position for the blades. A gauge diameter of the blades may be based on the locking positions of the locking collar.

Abstract: A downhole rotary tool for comminuting tubing in a borehole comprises a tool body and a plurality of cutting assemblies projecting from or extensible from the tool body and distributed azimuthally around a longitudinal axis of the tool body. Each cutting assembly comprises a supporting structure and a plurality of cutters with cutting surfaces of hard material. The rotating tool is advanced into initial contact with the tubing to commence milling axially along the tubing and then advanced further to continue milling the tubing, At least one cutting assembly has material which is softer than the hard faces of the cutters and is positioned to contact the tubing at the initial contact and delay contact between at least one hard surfaced cutter and the tubing.