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Well-Vac v.2Service Manual

(2-1/8")

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February 15, 2007

This publication is the property of BJ Services Company and may not be reproduced or translated without priorwritten consent from the BJ Technical Publication Department, Calgary, Canada.

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Read Manual Before Servicing Tool

Please read and understand this service manual with all safety instructions beforeassembling or disassembling the tool. Serious injury or death may result from a failure to

follow safety precautions.

Keep this service manual with the tool so it is always available even if the tool is shipped toanother location. Move forward through an assembly or disassembly section becausewarnings may only be found in the appropriate section. Use a placeholder, like a sticky note,to mark your place in the manual so that you do not inadvertently miss a step.

Perform the instructions at each numbered step: to avoid mishap, injury or death; to ensure asuccessfully completed job; to prevent work stoppage due to tool breakdown; and to

maximize tool part life.

Version NumberUpdated parts in a tool are indicated by a new version number applied to the manual title. (If

a version number does not appear on a manual name it is because there is more than oneGeneral Assembly drawing in the manual. Look to each drawing for the version number.)

Copyright DateUpdates to a manual are indicated by a new copyright date. Use the manual with the mostcurrent copyright date for the version of tool to be serviced.

Updating Manuals(1) Determine the version of the tool in hand. (The version number should be on the tool tag.The original version number will be in the original manual shipped with the tool. If parts of adifferent design have been introduced, then the version of the tool has changed and theoriginal manual no longer reflects the updated tool.)

(2) Find the manual that corresponds to the appropriate version of tool in the Lotus Notes

Coiled Tubing Library database. If the copyright date in the database is newer than thecopyright date on the manual in hand, then replace the outdated manual with the updatedmanual.

Print an Original - Do Not PhotocopyPrint rather than photocopy service manuals to prevent loss of photographic detail.

Symbols Used in Service Manuals

A caution sign indicates a potentially hazardous situation which, if notavoided, may result in injury. Caution signs draw attention to unsafe practices and

procedures where parts may be damaged if mishandled.

Warning signs indicate a potentially hazardous situation which, if notavoided, could result in death or serious injury.

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Service Manual Conventions

The illustrations below simply show the assembly/disassembly conventions for this manualand are not parts for this tool.

Left-most part name corresponds to left-most part in a photo.

Left-most item # corresponds to left-most part in a photo. (All item numbers can bereferenced on the General Assembly drawing in the appendix of this manual.)

Uphole end is always shown on the left in a photo.

Upper Filter Spaceritem 26

Filter Tubeitem 28

O-Rings shown on the end of a part, go inside the part.

O-Rings shown to the side of a part, go outside the part.

Diffuseritem 30

O-Ring 213item 217

O-Ring 209item 216

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Quality ControlUpdate the QC (Quality Control) Schedule with the date and description of service. Thereare two ways to do this:

1. Use the Tool Preventative Maintenance program on Lotus Notes.

2. Complete the forms in the Preventative Maintenance section in this manual.

Essential Disassembly Requirements1. Remove and discard all O-rings.

2. Use parmalee wrenches (not a vice or pipe wrench) to disassemble the tool.

Essential Assembly Requirements1. Lubricate all threads with Jet Lube SS-30 prior to make up.

2. Install new O-Rings only. If tool proves difficult to slip an O-ring over, apply grease tothe surface.

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Well-Vac v.2 Service Manual (2-1/8") Page: i

Table of ContentsOverview .......................................................................................... 1

Appl ication ........................................................................................................ 1Equipment Requirements ................................................................................. 2

Surface Equipment........................................................................................ 3Site Equipment.............................................................................................. 4

Speci fications .................................................................................. 5

How i t works .................................................................................... 7

Operational Mode ............................................................................ 9How Mode Swi tching Occurs ........................................................................... 9Determining Mode Setting .............................................................................. 10Sand Cleanout in Vertical Wells ..................................................................... 11

BHA / Cleanout Operation ............................................................ 13

Chemicals ........................................................................................................ 13Surface Tests................................................................................................... 13Run-in-Hole Procedure ................................................................................... 14Sand Removal Mode (Sand-Vac mode) ........................................................ 14Fluid Removal Mode (Well-Vac mode) ........................................................... 15Stuck-in-hole procedure ................................................................................. 16

Testing ........................................................................................... 19Testing in the Shop ......................................................................................... 19

Filter Assembly, Fluid Flow Guide and Nozzle Pressure Tests.................... 19Shift Mechanism Pressure Test................................................................... 21

Testing in the Field.......................................................................................... 22

Coil Connection Pressure Test.................................................................... 23Surface Test of Tool Function...................................................................... 25

Assembly ....................................................................................... 27Tool Assembly................................................................................................. 27

Power Nozzle.............................................................................................. 33Nozzle Calibration....................................................................................... 35

Options ............................................................................................................ 39Sand-Vac Lockout Option............................................................................ 39Well-Vac Lockout Option............................................................................. 40Shift Mechanism Option.............................................................................. 41

Bullnose Nozzle............................................................................................... 52Roll-on to Concentr ic Coil Connection (CCT) ............................................... 56

2 x 1 (5.08 cm x 2.54 cm) Concentric Coil Connection (CCT) ................... 56Loading and Transporting Concentr ic Coiled Tubing .................................. 62

Injector Loading Gear Assembly.................................................................. 62Assembly Shear Sub-Assembly .................................................................. 64

Installing Shear Rings.................................................................................. 64

Disassembly .................................................................................. 71Disassembly Shear Sub-Assembly ............................................................. 71

Removing Shear Rings................................................................................ 72

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Page: ii Well-Vac v.2 Service Manual (2-1/8")

Bullnose Nozzle............................................................................................... 76Options ............................................................................................................ 80

Well-Vac Lockout Option............................................................................. 80Sand-Vac Lockout Option............................................................................ 81Shift Mechanism Option.............................................................................. 82

Tool Disassembly............................................................................................ 91

Power Nozzle.............................................................................................. 96

Troubleshooting .......................................................................... 103

Appendix ...................................................................................... 105

Parts Kit

DrawingsGeneral AssemblyFishing

1.5 - .75 Concentric Tubing Surface Connector1.5 1 Concentric Tubing Surface Connector2 1 Concentric Tubing Surface ConnectorTubing Surface Connector Fitting Weld

Welding InformationWelding Procedure SpecificationProcedure Qualification Record (PQR)

Table of Item Numbers

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Well-Vac v.2 Service Manual (2-1/8") Page: 1

OverviewThe Well-Vac (2-1/8") tool is effective for removing detrimental sand accumulations -

primarily from low-pressure horizontal and vertical wells - and for removing drilling fluids in

new wells. Sand is removed without hydrostatic loading of the reservoir. The processincorporates a specialized jet pump that is run on concentric coiled tubing (CCT).

A power fluid is injected down the inner tubing string. In cleaning mode, part of the flow isdiverted to nozzles at the front of the tool to fluidize the sand. The remaining fluid passesthrough the jet pump orifice, creating a low-pressure zone that sucks in the sand from the

well. The sand slurry then returns to surface through the coil-coil annulus.

The Well-Vac tool offers the following advantages:

continuous cleaning operations

proven jet pump technology

steady wellbore pressure conditions throughout the cleaning operation

utilization of formation water as power circulation fluid

option to operate in either cleaning mode with external jets operating or production modewithout external jets

ApplicationThe Well-Vac is designed for use with a concentric (coil within coil) coiled tubing (CCT)string, to clean out a wellbore. CCT provides a constant flow area for returns, and hence, aconstant velocity to keep the fill in suspension during transport to surface.

In most cases this procedure is performed in wells that will not support a column of fluid

(low-formation pressures) or wells with long, highly deviated sections where high annularvelocities are unattainable due to the coiled tubing string limiting the flow.

Sand fill in a highly deviated wellbore will fall to the bottom or low side of the well as thefluid flows along the deviated section. Using conventional sand cleanout procedures, the sand

is cleaned out and fluidized ahead of the coiled tubing. The sand then falls back to the bottomof the wellbore and on top of the coiled tubing, due to low fluid velocities in the horizontal

and build sections of the well. This usually disrupts the natural sorting and bridging that hastaken place behind the liner during the wells production. This can cause the formation tohave an increase in fill production, causing a loss in oil and gas production.

In the case of a vertical well, the column of sand is fluidized in front of the tool and lifted tothe intake ports for transport to surface.

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Page: 2 Well-Vac v.1 Service Manual (2-1/2")

Slotted Liner

Natural Sorting / Bridging

Influx / Sloughing

Settled Fines

Figure 1 - Horizontal Wellbore Cross Section - with slotted liner

The second main application for the Well-Vac is to remove drilling fluids from newly drilledwells and to aid in new well production from all zones.

Equipment RequirementsThe following equipment is required:

An additional rotating joint. (The original joint fitted to the drum for the power fluidstream should continue to serve this purpose). The new joint is required to handle thereturn fluid flow consisting of fluids and solids. This must be a new pattern of joint

(sourced from BOWEN, Hydrarig or, possibly, others) that should be of a 2" nominal sizeand designed to handle solids in the flow.

A Concentric Coiled Tubing (CCT) Surface Connector as diagrammed in the appendix of

this manual. Two isolation valves (2" plug valves) with WEC01502 connections.

Connecting pipe. Manufacture 1" and 2" connecting pipe to connect rotating joints to theCCT Surface Connector. Details for this connecting pipe must be determined locallyafter selecting a reel.

Reel size and tubing length dependent on the well profile.

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Surface EquipmentSurface equipment includes:

special alterations to create a CCT reel complete with a rotating joint for abrasive returns.

the BJ Services Concentric Coiled Tubing Surface Connector. all necessary valves and piping.

Figure 2 Surface Equipment Schematic

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Site Equipment

HP

F FM P

FM P

Return Line

DualCompartmentRig Tank

400 bbl Tanks

Feed Line

Pressure Truck

Top-filling

Crane Truck

Wellhead,Injector &

SupportStructure

CCT Reel Unit

Sand-Vac

Pumperwith FilterSystem

P

HP

F

Flow Meter

PressureTransducer

High Pressure Filter

Legend:

FM

Figure 3 Well-Vac Site Equipment Schematic

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SpecificationsIMPERIAL METRIC

Overall length 76 - 91 1.9 m 2.3 m

Outside diameter 2-1/8 54.0 mm

Minimum operating temperature 5 F -15 C

Maximum operating temperature

depends on aluminum shear rings...

depends on O-Ring...230F

390 F

110C

200 C

Shipping weight including cases and hand tools 225 lbs 102 kg

Gross dry weight 75 lbs 34 kg

Power fluid 10,000 psi 68.9 MPaMaximum internaltool pressure

Annulus Return 6,800 psi 46.9 MPa

Aluminum rings no

holesAcid soluble

Brass ring no holes

Acid resistant

21,000 lbs 9,341 daN

Aluminum rings 8 holesAcid soluble

Tensile Pull to Shear

Note: Tool pressure

reduces Pull to Shear byapproximately 15,000lbs at maximum internal

tool pressBrass ring 8 holes

Acid resistant

16,000 lbs 7,117 daN

Minimum wellbore diameter 2.188" 55.6 mm

Concentric Coiled Tubing sizes available 2" x 1" 5.08 cm x2.54 cm

O-RingsViton 75 duro

Grease/lubricants - CV 500 Joint Grease- White Lubriplate

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How it worksThe Well-Vac system is based on proven jet pump principles. Modified and patented for useon CCT, the pump has been configured to optimise both sand intake rates and lift pressures.

Swirl jets provide energy to fluidize settled sand in the wellbore, prior to being drawn inthrough the intake ports. The Well-Vac was designed to provide continuous sand removal

and cleaning with minimum well disturbance.

Low

Velocity

High

Pressure

Low Pressure

Nozzle

Throat

Intake Ports

(fluid and wellbore material)

High Velocity

Intake Ports

(fluid and wellbore material)

Figure 4 - Principles of Jet Pumps

The power fluid is pumped through the inner coil of the concentric string to a power nozzle.The low pressure, high velocity stream exiting the nozzle creates a localized drawdown,

enabling sand and fluid to be produced from the wellbore. The combined streams pass into adiffuser, where high velocity is converted into high pressure. The pressure at this point is

high enough to lift fluid to surface, while the liquid velocity in the CCT annulus is highenough to transport sand.

Figure 5 - CCT / Well-VacTM

Flow Diagram

The Well-Vac has a 2-1/8" (5.40 cm) OD that allows it to be used in liner or tubular sizes2-3/16" (5.56 cm) or larger.

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Operational ModeThe Well-Vac operates in two modes - Well-Vac orSand-Vac - with various Power

Nozzles installed.

In Sand-Vac mode, the tool is designed to clean out fill while running in the hole and pullingout of the hole. This is accomplished by having both forward and reverse swirl nozzles. TheSand-Vac mode operates in a roughly balanced flow condition (suction rate equals Swirl

Nozzle flow rate). For example, with a #8 Nozzle/Throat setup the typical pump rates would

be 120 L/min (0.75 bbl/min) power fluid and 120 L/min (0.75 bbl/min) return fluid.

In Well-Vac mode, the tool is designed to produce the well on the returns, so the return fluid

flow rate usually exceeds the power fluid flow rate. Again, using the #8 Nozzle/Throat setup,the typical flow rates would be 90 L/min (0.56 bbl/min) power fluid and 120 L/min (0.75

bbl/min) return fluid.

The Well-Vac operator must be ful ly aware of the tool 's mode setting. Runningthe tool in the incorrect mode will not allow the tool to perform the required job, and will

result in an incomplete job.

How Mode Switching OccursSwitching between Well-Vac and Sand-Vac mode is achieved by a spring-loaded valve

within the J-Slot assembly. Flow through the swirl jets is toggled on or off.

As pressure inside the tool increases, theJ-Slot Shaftmoves against a stack of disk springs.A pressure of approximately 5,300 psi (using high pressure springs) or 3000 psi (using low

pressure springs) is required to move the path of flow across a high-pressure seal and into aposition where the swirl jets can be activated. Once the flow is diverted to these jets, achange in area on which the pressure acts is incurred, and the J-Slot shuttles completely open.

To return the shaft back across the high-pressure seal, allow the pressure to fall belowapproximately 2700 psi (for high pressure springs) or 1000 psi (for low pressure springs) to

overcome the difference in areas.

With each pressure cycle, the J-Slot alternates between long and short stroke positions. The

J-Slot will not shift between modes without the operator first allowing the pressure to drop tobelow the specified pressure as follows:

SPRINGS PRESSURE (PSI) VALVE MOVES TO

High Pressure 5300 Open

High Pressure 2700 Close

Low Pressure 3000 Open

Low Pressure 1000 Close

If a sufficient pressure is not achieved, the J-Slot remains in its normal jets off position.

To an untrained operator, it may appear that the tool is in Well-Vac mode during a surfacetest whereas the tool may actually be in Sand-Vac mode with insufficient tool pressure to

activate the jets. When determining the tool mode, explained in the next section, be sure toobtain a pump pressure beyond that needed to overcome the springs (i.e. 6000 7000 psi)

before assuming which mode the tool is in.

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MODE: WELL-VAC SAND-VAC

External jets: off On

J-slot shaft: short stroke long stroke

When operating the Well-Vac 2-1/8" in deep wells, take special carewhen shifting modes. A deep well may provide enough hydrostatic pressure in the tubing toinhibit J-Slot Shifting. In order to shift from one mode to the other, the tool pressure must

drop below 2700 psi (for high pressure springs) at the tool. Shutting down the surface pumpeliminates pump pressure, and closing the reel valves keeps water from siphoning fromsurface and maintaining hydrostatic head. Even though the operator will see the pressurequickly drop to zero at surface, time is required to drain the column.

To obtain a reset in this case, shut down the pump and close the power fluid reel valve for at

least 10 minutes to allow the water column in the tubing string to drain. When pumping iscontinued, the tool will shift into the next mode.

As long as flow falls out of the bottom hole assembly (BHA), flow will be drawn in at surfaceunless the valve is closed between the tank and the coiled tubing. Failure to close the valve atsurface will result in the tool remaining under full hydrostatic pressure until the tank iscompletely drained.

Determining Mode SettingTo determine which mode setting the tool is operating in while down hole:

1. Reduce the flow rate and pressure to zero. If the BHA is deeper than [850 metres (3000ft) low pressure springs] or [1850 metres (6000 ft) high pressure springs], it may benecessary to close the power fluid reel valve and wait 10 minutes for the coiled tubing

water column to drain into the well. Refill the coiled tubing in a slow, cautious manner.

2. Increase flow rate on the tool to a value not exceeding the predicted flow rate provided byCIRCA for the Well-Vac mode.

3. After the coiled tubing is full, bring the tool to full operational pressure and note the flowrate to the tool.

4. Repeat steps 1 and 2, then bring tool up to operational pressure again and note flow rate

to the tool. the lowerflow rate is the Well-Vac flow rate (Swirl Nozzles not activated)

the higherflow rate is the Sand-Vac flow rate (Swirl Nozzles activated)

From this point in the job you should be able to determine mode setting from flow rate valuesalone. If the job has been correctly modeled in CIRCA these flow rates should match CIRCA

modeling for both Well-Vac and Sand-Vac modes.

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The swirl nozzles will stay "on" below the pressure needed to activate them. To allow propermode shifting always reduce the flow pressure to zero for at least 5-10 minutes before

pressuring up into the next mode.

Sand Cleanout in Vertical WellsThe Well-Vac now performs sand cleanout operations in vertical gas or oil wells but this typeof sand cleanout offers unique challenges over a horizontal sand cleanout - primarily

controlling RIH speeds and tool depth in fill.

Controlling RIH speedsControlling RIH speed is critical for preventing excessive ThroatandNozzle erosion.

Since the wellbore is 100% full of sand in the cleanout region, the tool can draw in excessivesand percentages of the wellbore fluid/sand slurry.

Increasing the RIH speed beyond what the tool can safely remove reduces the fluidizationcapacity of the jetting nozzles. This reduced capacity allows higher sand percentages to enter

the tool. Higher sand percentages may result in:

overloading of the return fluid in the CCT annulus. It also risks extremely high erosion onthe Throatface andNozzle tip. If left uncorrected this erosion might force a trip tosurface to replace these parts prematurely.

hydrostatic pressure of the return fluid column exceeding the pressure generated by thejet pump causing returns to decrease or stop completely. The CCT annulus could becomeplugged, requiring a partial trip to surface.

Controlling Tool Depth in FillControlling the tool depth under the fill column is important for preventing a stuck-in-holecondition. While operating the tool in Sand-Vac mode under large fill columns (150'-200')

testing has shown no problems in either RIH or POOH conditions, but this is an extremelyrisky method of tool operation.

If the jetting nozzles shut down for any reason and cannot be restarted, the possibility ofbecoming stuck in as little as 20' of fill is very high. Maintaining a penetration into fill depth

of 10'-20' during the entire job is optimum for preventing a stuck-in-hole situation in case ofjetting nozzle shutdown or failure.

Being diligent about RIH rates and the tool depth under fill aids significantly in performing asuccessful sand cleanout in any vertical well.

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BHA / Cleanout Operation

ChemicalsA friction reducer (i.e. FRW-14) is normally used to reduce the fluid friction in the power andreturn sides of the CCT. Concentrations generally range from 0.75 to 1 gal/1000 gal (0.75 to1 L/1000 litres).

A dispersant is often added to the water (power fluid) to reduce viscosity of the return flowwhen cleaning a heavy oil well,. The dispersant can also prevent the heavy oil from plugging

the external screen on the tool when the tool is in Sand-Vac mode.

The dispersant creates a water-external emulsion with agitation, which effectively reduces theviscosity of the heavy oil. The emulsion breaks when the agitation is discontinued. Two

heavy oil dispersants are: Baker Petrolite PAW-4D and Unichems Techni Sperse 2568. Alab test should be done to:

confirm the dispersant's compatibility and effectiveness in the water and oil mixture.

determine the most effective concentration, with a concentration of 0.50 gal/1000 gal (0.5L/1000 litres) typically used.

For light or medium density oil wells perform compatibility tests to ensure an oil externalemulsion will not form with mixing.

Surface TestsPerform the following tests before starting to run in hole:

manual shifting tests using a drill press or vice.

pressure test the Shift Mechanism following the procedures in the Testing in the Shopsection of this manual.

pressure test Roll-on Connectors using the proper connections to ensure there are noleaks.

function test the tool on surface before RIH to ensure it is shifting properly, the swirl jetsare functioning properly and there are no leaks in Well-Vac mode.

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Run-in-Hole ProcedureTo conserve power fluid, the Well-Vac is typically run in hole at a reduced pump rate fromthat predicted by CIRCA, or no pump rate at all with surface valving closed. Pumping can bein either Sand-Vac or Well-Vac modes.

At a certain point above the cleanout depth or suspected sand top, stop the CCT and set theoperational injection rate with the tool in Sand-Vac mode. Use CIRCA to determine the

proper injection and return rates for the given Throat/ Nozzle combination and the wellparameters. With the proper injection pressure and rates confirmed, running in hole can be

continued. In a gas well, complete fluid circulation with no gas in the returns should beestablished before proceeding with the cleanout. Accurate return flow measurements aredifficult to impossible when dealing with gasified return fluid.

A safe RIH rate through production tubing sections depends on CCT size and completionrestrictions. A typical RIH rate for 2 (5.03 cm) and 1 (2.54 cm) CCT would be 33 ft/min

(10 meters/min).

Sand Removal Mode (Sand-Vac mode)Safe penetration rates depend on the:

size of the completion,

percentage of sand in the completion,

suction rate from the well, and

vertical or horizontal cleanout.

The suction rate for a particular CCT size depends on BHP (Bottom Hole Pressure) and thechosen Throat and Nozzle sizes. CIRCA analysis is important to determine the proper Throat

/ Nozzle sizes and corresponding pump rates so that the suction and cleaning or RIH rates are

optimised.

Throat wear will generally reduce the jet pump performance. If large sand volumes areproduced from the well, Throat erosion may reduce performance or suction rate to the pointthat the tool should be pulled from the hole and redressed.

Check return flow often (at least every 15 minutes) using pail tests to determine the sandconcentration in the return flow. If sand concentrations are nil or small then the penetration

rate can be increased. However, monitor the weight gauge closely for weight losses that mayindicate a large sand bridge has been tagged.

A small reduction in the return rate often indicates that large sand concentrations are on their

way to surface. It is important to know the bottoms-up time so that tool depth can becorrelated with the sand concentrations.

Monitor injection pressure closely, along with the injection and return rates, to ensure the toolis functioning properly. A sudden drop in injection pressure (normally accompanied by adrop in return rate) usually indicates that the tool has developed a leak or the Power Nozzle is

damaged.

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Conduct pull tests regularly (at least every 230 ft or 70 meters) when cleaning sand from ahorizontal section. If high sand concentrations (i.e. 3 % sand) are seen at surface then the pull

rate frequency should be increased. Any time a weight loss is observed a pull test should beconducted.

A large and sudden drop in the return rate is often due to the external screens on the tool

becoming plugged. To alleviate this plugging, shut down the surface pump for a few secondsto allow the screens to be flushed. In a vertical or near vertical well if the screens are flushed

with sand in the concentric annulus, the sand will fall back into the tool and may plug it up.

Pumping down the backside (annulus of CCT and completion) may be used to maintain the

well in an overbalanced condition.

Fluid Removal Mode (Well-Vac mode)The Well-Vac is normally used in fluid removal mode for the following applications:

1. Fluid or mud removal after a sand cleanout.

2. Mud removal from the horizontal section of a newly-drilled horizontal well or muddamage removal from a previously producing well.

3. Production evaluation in the horizontal section of a conventional or horizontal well.

For applications 2 and 3, the fluid removal operation is normally initiated after the tool has

been run to the toe of the well in Sand-Vac mode. Generally, significant sand concentrationsare not expected in the completion in these applications and the tool can be run at higher

penetration rates than for a typical sand removal operation. Penetration rates may vary from3.3 to 16.4 ft/min (1 to 5 meters/min).

Continue to monitor returns closely during the RIH because whatever is removed from the

well is important and may influence the procedure during the POOH.

The pull rate from the toe will generally depend on the net suction from the well and the total

fluid recovery volume that the customer needs to remove from each section of the well.

During a fluid removal operation it is important to monitor the total volume of fluid beingremoved from the well.

Pail sampling is important to determine the percentages of oil, mud, and solids.

CIRCA analysis is important to optimize the Throat / Nozzle sizes.

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Stuck-in-hole procedureIf the CCT becomes stuck in the wellbore, there is a built-in release system in the Well-Vacthat can be used. The release system is the last option in the event that the CCT becomesstuck. Use the following procedures before using the release system.

1. Increase the fluid rate down the inner coiled tubing to the Well-Vac and start to work thepipe in and out of the hole. If the pipe becomes free, continue to pull out of the hole.Assess the tool and the returns. If sand is present, continue to pull out and cleanout before

starting to run into the hole.

2. Try to work the pipe at different speeds, if possible (0.15 -5.0 m/min. or 0.5-16 ft/min,also 4500 daN or 10,000 lbs). If the string starts to pull tight, only pull over by 4500 daNor 10,000 lbs over string weight, (consult the CIRCA information). Once the weight has

been reached, stop and watch to see if the weight starts to return back to the stringweight. If the weight returns, continue to work the pipe until the string is completely free

before continuing with the cleanout.

3. If the tool can be run into the hole, continue to do so but only short distances of 20-50meters (65-164 ft) before the tool is pulled back to the tight spot. Ensure that the tool can

be retrieved back through the tight spot before continuing to TD.

4. A slug of diesel (or other solvent) can be pumped down the annulus and allowed to soakaround the tool. This will work provided the tool is still very close to the build section ofthe well. This slug of diesel (or other solvent) can also be pumped down the CCT.

5. While working the pipe, fluid may also be pumped down the annulus at high rates asdictated by completion size.

6. The returns to the rig tank can be closed and fluid can be pumped down both inner andouter strings. This will give a high rate surge down hole and may dislodge the coiledtubing. Do not exceed 46.8 Mpa (6800 psi). Continue to work the pipe during this

pumping operation.

7. Nitrogen gas can be pumped down the annulus of the well and pressure held while

continuing to work the pipe.

8. Water gel plugs can be pumped down the annulus of the coiled tubing and displaced withnitrogen gas. This will act as a plug sweep to remove the sand bridge.

9. Spot light oil down the annulus and allow to soak for 12-24 hours, then begin pulling outof hole.

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10.In a pipe stuck situation, displace the complete coiled tubing to nitrogen gas. Thisplaces the pipe in a PIPE LITE situation. Continue to work the pipe. Try this beforeattempting the overpull to release the tool.

11.A gel pill can be spotted down around the tool and allowed to sit for 15 minutes beforecontinuing to work the pipe. The gel can also be foamed as another method of freeingstuck coiled tubing.

If all of the above measures fail, the Well-Vac may have to be released off thetubing.

1. The Well-Vac has built in Shear Rings that allow the CCT to be pulled off the tool. TheShear Rings are available in both aluminum and brass (for acid service).If the tool becomes stuck, the CCT may be pulled off the tool leaving almost the entiretool in the hole. Shear Rings come in two pull strengths - 21,400 lbs (9,519 daN) and

15,800 lbs (7,028 daN) at zero tool pressure. When the tool has maximum operatingpressures applied to it, the pull to shear reduces by 14,700 lbs (6500 daN).Continue topump down the inner string to keep the fluid in the well moving.

2. If the release assembly fails to shear, it is possible that this is a pipe stuck, not toolstuck situation.

3. If the tool will not shear, 500 liters (3.14 bbl) of 15% HCl can be spotted around the tooland allowed to soak for 30 minutes to acidize the aluminum shear rings. If the brass shearrings are in place, this method will not help to release the tool. Again, attempt an overpullto release the tool.

In all cases, perform CIRCA ANALYSIS and noti fy the appropriate personnel.

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TestingSpecific sections of the Well-Vac require testing as the tool is assembled. Testing should only

be performed by a qualified technician using special test fixtures. All testing fixtures are

supplied with the tool.

Tests take place in the shop and in the field.

Shop tests include:

Filter assembly, Fluid flow guide and nozzle pressure test

Shifting mechanism pressure test

Shifting mechanism function test (shown in the Assembly section of this manual)

Field tests include:

Coil connection pressure test

Surface test of tool function

Testing in the ShopIf the Well-Vac is stored for any duration following this test, use an oil/inhibited wateremulsion in the pump for the test.

Filter Assembly, Fluid Flow Guide and Nozzle Pressure TestsPressure test the assembly to determine if there are any leaks.

Testing Procedure

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Pressure Testing LayoutDuring this test theBlank Power Nozzle must be in place (no thru hole). If a regular

operational Power Nozzle is used, pressure will not be contained within the tool.

1. Assemble the tool up to and including step 13 on page 39 of this manual.

Note: Use theBlank Power Nozzle instead of an operational Power Nozzle.

2. Prepare Test Capby plugging NPT hole with a NPT plug and threading onto theBurst Disk Replacement Crossover.

3. Place the O-Ring 113 onto Test Fixture.

4. Thread an approximately 5 long, NPT extension into Test Fixture and place it insideTest Cap with the extension protruding through NPT hole.

5. Thread the correct fitting onto the extension for later attachment to the test pump.

6. Pre-fill the tool with test fluid to minimize the volume required through the pump.

7. ThreadTest Cap assembly onto Pin To Pin Crossover.

8. Place the tool test section in a safe location, out of direct line of sight from other people.

9. Connect the test pump to the fittings on the Test Fixture.

10.Begin to pressure up the tool. Start slowly and watch for leaks as the pressure builds. DONOT EXCEED 10,000 psi (68.9 MPa). Once 10,000 psi (68.9 MPa) has been reached,allow it to sit for a few seconds to ensure there are no leaks.

11.Bleed off pressure and disconnect the test pump.

12.Drain fluid from the tool and remove test fixtures.

13.Ensure that you replace theBlank Power Nozzle with the operational Power Nozzle in thetool, and follow the calibration procedures as outlined in the Assembly section of this

manual.

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Shift Mechanism Pressure TestTest the Shift Mechanism pressure in the shop to:

ensure that the Shift Mechanism is not leaking

check that it is shifting at the correct pressure

This test requires pressure to 8000 psi (55.2 MPa) so take care whenperforming the test.

If the Shift Mechanism function test outlined in the assembly section was performed properly

the Shift Mechanism should start off in Well-Vac mode during initial pressure up. If this isnot the case you won't be able to pressure up the shifting mechanism and it will have to beremoved and placed in a press to cycle the J-Slot into the correct position. Refer to thesection, Shift Mechanism Function Test, in this manual for instructions on how to achievethis.

Shift Mechanism Testing Procedure J -Slot External Housing(item 14)

J -Slot Housing Extension(item 13)

Bullnose Assembly

O-ring #125(item 213)

Test Cap(item T8)

1/4" NPTExtensionFitting

Shift Mechanism Testing Layout

1. Complete the tool assembly procedures from steps 1 to 26 in the Shift Mechanism Optionsection of this manual.

2. Prepare Test Cap with O-Ring 125 and fittings needed to connect it to the hand pump.

3. ThreadTest Cap intoJ-Slot Housing Extension.

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4. Cover the end of theJ-Slot External Housing with some paper towel to prevent fluidspill.

5. Place test section in a safe area away from direct line of sight of other people.

6. Connect the hand pump to the fitting on Test Cap.

7. Slowly begin to pressure up the Shift Mechanism. Increase the pressure to 8000 psi (55.2MPa). DO NOT EXCEED 8000 psi (55.2 MPa). Hold pressure for a few seconds.

8. If the Shift Mechanism will not pressure up beyond 5300 psi (high pressure springs) or3000 psi (low pressure springs), the J-Slot is in Sand-Vac mode. Relieve pressure, andremove the Test Cap and theJ-Slot Housing Extension. Drain fluid and perform the ShiftMechanism Function Test as described in the assembly section of this manual ensuringthat the next shift will be into Well-Vac mode.

9. Repeat testing procedure up to this point.

10.If the Shift Mechanism will not hold this pressure, disassemble and inspect all seals. Re-assemble according to the procedures in the assembly section of this manual.

11.Repeat testing procedure up to this point.

12.If pressure holds, bleed off pressure back to 0 psi.

13.Start to slowly increase pressure on the Shift Mechanism. Watch the pressure gauge

closely. When the pressure reaches approximately 5300 psi, (high pressure springs) or3000 psi (low pressure springs) the Shift Mechanism will shift to Sand-Vac mode and the

pressure will drop, at which time you will not be able to increase pressure with the handpump. Fluid should also have leaked out the front of theJ-Slot External Housing and into

the paper towel.

14.Relieve residual pressure, drain fluid from the tool, and remove Test Cap.

Testing in the FieldTake precautions to avoid plugging swirl jet orifice with debris. Tool function will beseverely compromised if this occurs.

Pig or pickle the coiled tubing prior to connecting the Well-Vac tool to avoid introducingdebris into the tool.

With all hand pump tests passed, the tool is ready to connect to the coiled tubing.

The coiled tubing should be prepared for the tool by having the correct roll-on connectorsattached.

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Fill coiled tubing with service fluid prior to testing.

Coil Connection Pressure TestTest the Coil Connection pressure in the field to fully pressure both roll-on connectors andcoiled tubing to operational pressures, for both the power side (10,000 psi or 68.9 MPa) and

return side (6800 psi or 46.9 MPa).

During the test of the power side of the tool the return side must be vented to the atmosphereso as not to place any pressure on the return side. When testing the return side, both the

power and return side of the tool will be pressurized.

Ensure that all personnel are aware of the dangers associated with high

pressure surface tests. Keep all non-essential personnel away from the area during testing.

Coil Connection Test Procedure - Return Side

Coil Connection (Return Side) Testing Layout

1. Install Shear sub assembly (assembled up to and including Roll-on and Filter Housing asdescribed in Installing Shear Rings onto the coiled tubing roll-on connectors.

2. Thread the extra Pin To Pin CrossoverontoRoll-on and Filter Housing.

3. ThreadTest Cap onto Pin To Pin Crossover.

4. Fill coil if not already full.

5. Close off return fluid flow.

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6. Begin pressurizing the tool, leaks will be obvious as this is now pressurizing the externalside of the tool.

7. Pressure coil to a maximum of 6800 psi (46.9 MPa), not any higher. Hold pressure for amoment and watch for leaks, then bleed system pressure back to zero.

8. Remove Test Cap from tool.

Coil Connection Test Procedure - Power Side

Coil Connection (Power Side) Testing Layout

1. Install Shear sub assembly (assembled up to and including Roll-on and Filter Housing asdescribed in Installing Shear Rings) onto the coiled tubing roll-on connectors.

2. Thread the extra Pin To Pin CrossoverontoRoll-on and Filter Housing.

3. Prepare Test Fixture by plugging the NPT hole with a NPT plug. Install O-Ring113.

4. Insert Test Fixture into Test Cap. Make sure to leave the NPT hole open so that anyleaks will be obvious.

5. ThreadTest Cap onto Pin To Pin Crossover, ensuring that the Test Fixture is properlyseated into Pin To Pin Crossover.

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6. Begin pressurizing up the coiled tubing while watching for leaks from the hole in the TestCap. Since you cannot see any part of the power fluid side this is the only place where

you will see fluid if it is leaking.

7. Pressure the coil to a maximum of 10,000 psi (68.9 MPa), not any higher. Hold

pressure there for a moment, then bleed the system back to zero.

8. Remove Test Cap andTest Fixture from tool.

Surface Test of Tool FunctionSurface test tool function in the field to:

test before going down hole with the tool

ensure that the tool functions in all modes

visually identify tool mode (Sand-Vac or Well-Vac) prior to RIH.

During this test, high velocity fluid will be jetting out of the swirl

nozzles. Place the down hole end of the tool in a barrel to contain the fluid jet. Serious injurycould result from being struck by fluid jet while the tool is in operation.

Tool will be in full operation under high pressure and flow rates. Keepall non-essential personnel away from the testing area.

Surface Testing Procedure

1. Shear sub assembly should already be connected to the coil tubing from the previoustests.

2. Remove the extra Pin To Pin CrossoverfromRoll-on and Filter Housing.

3. Connect the down hole tool assembly toRoll-on Housing.

4. Place down hole end of tool in a barrel so that the fluid from the swirl jets will becontained in the barrel.

5. Tool should be in Sand-Vac mode if the proper procedure for the Shifting Mechanismtest was followed.

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6. Begin to pressure up the tool. As the shifting flow rate approaches, watch for a pressuredrop. If no drop in pressure occurs then the tool is in Well-Vac mode. If a drop in

pressure occurs then the tool is in Sand-Vac mode. If the tool shifted into Sand-Vac modeconfirm that it shifted at approximately the correct flow rate.

7. Continue to increase flow rate until the maximum flow rate for the appropriate mode isachieved.

8. Reduce pressure to zero and begin to re-pressurize the tool.

9. Take the tool to the maximum flow rate for the appropriate mode.

10.Reduce pressure to zero.

11.Remove the tool from barrel.

The tool is now fully tested and ready for down hole use.

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AssemblyApply CV 500 Joint grease to all threads and O-Rings unless otherwise stated.

Tool Assembly

1. ThreadFilter Lower NPT Spaceronto Power Fluid Filter.Note: Use Teflon tape on threads.

Power Fluid Filteritem 27

Filter Lower NPT Spaceritem 28

2. Install two ofO-Ring 123 onto Filter Lower NPT Spacer.Install two ofO-Ring 113 onto end ofFilter Lower NPT Spacer.


O-Ring 123item 212

O-Ring 123item 212

O-Ring 113item 205

O-Ring 113item 205

3. Install two ofO-Ring 113 onto end ofFilter Upper Spacer.Install two ofO-Ring 123 onto Filter Upper Spacer.

Filter Upper Spaceritem 25

O-Ring 113item 205

O-Ring 113item 205

O-Ring 123item 212

O-Ring 123item 212

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4. Slide Filter Lower NPT Spacerinto Filter Tube.

Filter Tubeitem 26


5. Push Filter Upper Spaceronto Filter Tube.


Filter Tubeitem 26

6. Install two sets of O-Rings and Back-up Rings (O-Ring 131 andSolid Back-up Ring 131 forma set) onto Pin To Pin Crossover.

Pin To Pin Crossoveritem 6

O-Ring 131item 217

Solid Back-up

Ring 131item 313

Solid Back-up

Ring 131item 313

O-Ring 131item 217

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7. Slide Pin To Pin CrossoveroverFilter Upper Spacer.Note: Notice that the Filter Tube end without wrench flats goes in to the Pin To PinCrossover.



8. Install two ofO-Ring 132 into theRoll-on and Filter Housing at the base of threads.

O-Ring 132item 218

Roll-on and Filter Housingitem 5

O-Ring 132item 218

9. ThreadFilter Housing onto the Pin To Pin Crossover.

Pin To Pin Crossoveritem 6 Filter Housingitem 7

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10.Install O-Ring 131 andSolid Back-up Ring 131 onto the up hole end ofFluid Exchanger.

Install three sets of O-Rings and Back-up Rings (O-Ring 129 andSolid Back-up Ring 129form a set) onto Fluid Exchanger.

Fluid Exchangeritem 8

O-Ring 131item 217

Solid Back-upRing 131

item 313

O-Ring 129item 216


item 312

O-Ring 129item 216


item 312

O-Ring 129item 216


item 312

11.ThreadRoll-on and Filter Housing onto the Fluid Exchanger.



12.Slide Fluid Exchange Tube overFluid Exchanger.


Fluid Exchange Tubeitem 9

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13.Install O-Ring 210 andSolid Back-up Ring 210 onto theDiffuser.For #4 and larger throats, use the longDiffuser.

For #3 and smaller throats, use the shortDiffuser.

Diffuseritem 29

O-Ring 210item 220

Solid Back-up Ring 210item 314

14.Insert O-Ring 207into down hole end of theDiffuser.

Diffuseritem 29

O-Ring 207item 219

15.Grease entireDiffuser. InstallDiffuserinto the Fluid Exchanger.


Diffuseritem 29

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16.Apply small amount of Locktite 242 to threads and insert the appropriate Throatinto ThroatRetainer Nut.

Note: Use CIRCA Job Design to determine the appropriate Throat.

Throatitem 30

Throat Retainer Nutitem 31

17.ThreadThroat Retainer Nutinto Fluid Exchanger.


Throat Retainer Nutitem 31

18.Install O-Ring 212 andSolid Back-up Ring 212 into up hole end ofSand Intake Crossover.Note: Ensure Back-Up Ring is on the down hole side of the O-Ring groove.

O-Ring 212item 221

Solid Back-up

Ring 212item 315

Sand Intake Crossoveritem 10

19.Install O-Ring 118andSolid Back-up Ring 118into down hole end ofSand Intake Crossover.Note: Ensure Back-Up Ring is on the uphole side of the O-Ring groove.


Solid Back-up

Ring 118item 306

O-Ring 118item 209

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20.ThreadFluid Exchangerinto Sand Intake Crossover.



Power Nozzle

1. Install O-Ring 013 andSolid Back-up Ring 013 into up hole end ofNozzle Retainer Cap.

Solid Back-up

Ring 013item 300

O Ring 013item 201

Nozzle Retainer Capitem 32

2. Install the appropriate Power Nozzle into theNozzle Retainer Cap.Note: Use CIRCA Job Design to determine the appropriate Power Nozzle.


Power Nozzleitem 33

3. Thread theNozzle Retainer Cap ontoNozzle Retainer.


Nozzle Retaineritem 34

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4. PlaceNozzle Retainer Cap into Power Nozzle Clamp.

Power Nozzle Clampitem T1


5. Place Power Nozzle Clamp into a vise. TightenNozzle Retainer Cap intoNozzle Retainer.Remove Power Nozzle assembly from the vise andPower Nozzle Clamp to continue.

Power Nozzle Clampitem T1



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Nozzle Calibration

1. Thread in and softly seatNozzle Retainerinto Sand Intake Crossover. Back outNozzleRetainerto achieve approximately 0.100 spacing (approx. 1.25 turns).



2. ThreadNozzle Retainer NutontoNozzle Retainer.


Nozzle Retainer Nutitem 250

3. ThreadNozzle Retainer LocknutontoNozzle Retainer.


Nozzle Retainer Locknutitem 251

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4. TightenNozzle Retainer NutandNozzle Retainer Locknutwith adjustable wrenches as shownand torque together.

NozzleRetainer Nut

item 250

NozzleRetainer

Locknutitem 251

5. Insert Sand Intake Crossoverinto the appropriate Suction Screen.

Note: Use Vertical Screen for wells up to approximately 80 inclination.


Suction Screenitem 11

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6. Install O-Ring 129 andSolid Back-up Ring 129 onto Sand Intake Crossover.


Solid Back-up

Ring 129item 312

O-Ring 129item 216

7. Thread theBullnose Crossoveronto the Sand Intake Crossover.


Bullnose Crossoveritem 12

8. Slide two sets of O-Rings and Back-up Rings [O-Ring 125 andSolid Back-up Ring 125 form

a set] onto either end of theBurst Disk Replacement Crossover.

O-Ring 125item 213

Solid Back-up

Ring 125item 309

Solid Back-up

Ring 125item 309

O-Ring 125item 213

Burst Disk Replacement Crossoveritem 19

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9. Install Spirlok, 1.188 into uphole end of theBurst Disk Replacement Crossover.

Spirlok, 1.188item 377



10.ThreadLee Filterinto Filter Spacer.

Lee Filteritem 100

Filter Spaceritem 42

11.Install Filter SpacerintoBurst Disk Replacement Crossover.

Lee Filteritem 100

Filter Spaceritem 42

12.Bend up the tab on the Spirlok, 1.188 and slide it into the down hole end groove of theBurstDisk Replacement Crossover.




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13.Thread theBullnose Crossoveronto theBurst Disk Replacement Crossover.

Bullnose Crossoveritem 12


Options

Sand-Vac Lockout Option

1. Slide O-Ring 122 andSolid Back-up Ring 122 onto downhole end ofSand-Vac Lockout.

Sand-Vac Lockoutitem 35

O-Ring 122item 211

Solid Back-up

Ring 122item 308

2. Insert O-Ring 010 into uphole end ofSand-Vac Lockout.

O-Ring 010item 200


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3. Thread the appropriateHalf Dog Orifice into uphole end ofSand-Vac Lockout.Note: Use Permatex High Temperature Thread Sealant onHalf Dog Orifice threads.Use CIRCA Job Design to determine the appropriateHalf Dog Orifice.

Half Dog Orificeitem 36


4. Insert Sand-Vac LockoutintoBurst Disk Replacement Crossover.



Well-Vac Lockout Option

1. Slide O-Ring 122 andSolid Back-up Ring 122 onto Well-Vac Lockout.

Well-Vac Lockoutitem 35

O-Ring 122item 211

Solid Back-up

Ring 122item 308

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2. Insert Well-Vac LockoutintoBurst Disk Replacement Crossover.



Shift Mechanism OptionNote: The Shift Mechanism Assembly is NOT a field-serviceable item. Return this item to

the service centre for servicing and rebuilding. Do not attempt to service this item withoutappropriate supervision and/or training.

Use white Lubriplate grease on the Shift Mechanism Assembly.

1. Install O-Ring 115 andSolid Back-up Ring 115 into up hole end ofJ-Slot Valve Body.

O-Ring 115item 207

Solid Back-up

Ring 115item 304

J-Slot Valve Bodyitem 39

2. Seat the smallerHP J-Slot Seal into O-Ring 132 and install into up hole end ofJ-Slot ValveBody.

HP J-Slot

Sealitem 317

O-Ring 132item 218


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3. Install O-Ring 119 andSolid Back-up Ring 119 onto theJ-Slot Valve Body.


O-Ring 119item 210

Solid Back-up

Ring 119item 307

4. Install Slydring into theJ-Slot Bearing Washer.

Slydringitem 316

J-Slot Bearing Washeritem 38

5. Apply grease to the outside of theJ-Slot Bearing Washerand install into the up hole end oftheJ-Slot Valve Body.

J-Slot Bearing Washeritem 38


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6. InstallDisc Spring onto theJ-Slot Shaftin the orientation shown in the accompanyingdiagram.

61 high pressureDisc Spring, or65 low pressureDisc Spring.

Note: LubricateJ-Slot Shaftwith grease before installingDisc Spring.

Disc Springitem 400

J-Slot Shaftitem 37

Orientation ofDisc Spring onJ-Slot Shaft

7. Grease and install O-Ring 110 andSolid Back-up Ring 110 onto theJ-Slot Shaft.

J-Slot Shaftitem 37

O-Ring 110item 204

Solid Back-up

Ring 110item 302

8. Install Thrust Bearing Washeronto theJ-Slot Shaft.

J-Slot Shaftitem 37

Thrust Bearing

Washeritem 376

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9. PackThrust Bearing with grease and install ontoJ-Slot Shaft.

J-Slot Shaftitem 37

Thrust

Bearingitem 325

10.GreaseJ-Slot Shaftand install into assembledJ-Slot Valve Body. Press into place.

J-Slot Shaft

item 37

J-Slot Valve Body

item 39

11.InsertJ-Slot Endinto theJ-Slot Valve Body. Tighten using a 5/16" Screwdriver.


J-Slot Enditem 40

12.Insert assembled Shift Mechanism into Spring Compressor Housing.

assembledShift Mechanism Spring Compressor Housingitem T2

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13.Orient slotted end ofSpring Compressor Endfacing down hole, then insert into SpringCompressor Housing.

Spring Compressor Enditem T3

Spring Compressor Housingitem T2

14.Place Spring Compressor Housing with assembled Shift Mechanism into a vise.Note: Tighten Spring Compressor Endusing a wrench.



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15.TightenJ-Slot Endwith a screwdriver.


J-Slot Enditem 40

16.UnthreadSpring Compressor Endfrom Spring Compressor Housing.Note: Reverse orientation ofSpring Compressor Endand thread into Spring CompressorHousing. Tighten using a wrench.



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17.Further tightenJ-Slot Endwith a screwdriver to ensure tightness.


J-Slot Enditem 40

18.Install two ofJ-Slot Pin intoJ-Slot Valve Body.Note:Disc Spring need to be slightly compressed. TheJ-Slot Shaftmay need to be rotated toensure pins fall into slots.

J-Slot Pinitem 350


J-Slot Pinitem 350

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19.Install O-Ring 019 ontoJ-Slot Valve Body to retainJ-Slot Pin.Note: Remove Shift Mechanism assembly from the vise andSpring Compressor Housing tocontinue.


O-Ring 019item 203

20.Insert O-Ring 010 intoJ-Slot Shaft.

O-Ring 010item 200

J-Slot Shaftitem 37

21.Thread the appropriateHalf Dog Orifice intoJ-Slot Shaft. Use PST onHalf Dog Orifice

threads.Note: Use CIRCA Job Design to determine the appropriateHalf Dog Orifice.


J-Slot Shaftitem 37

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22.Install O-Ring 125 andSolid Back-up Ring 125 ontoJ-Slot External Housing.

J-Slot External Housingitem 14

Solid Back-up

Ring 125item 309

O-Ring 125item 213

23.Insert assembled Shift Mechanism intoJ-Slot External Housing.

Assembled Shift Mechanism J-Slot External Housingitem 14

24.Perform the Shift Mechanism Function Test next.

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Shift Mechanism Function TestObserve the following cautions during the function testing procedure:

rotation of theJ-Slot Shaft

alternate long and short press strokes

Note: Leave the Shift Mechanism so that the next stroke will be a short one (i.e. the laststroke was a long one).

1. Using a drill press, test that the Shift Mechanism can be successfully compressed into theJ-Slot External Housing to the depth shown in the picture below.

2. Pressure test this device.

Drill Press

assembled Shift Mechanism


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Shift Mechanism Option Assembly contd

25.Install O-Ring 125 andSolid Back-up Ring 125 ontoJ-Slot Housing Extension.

J-Slot Housing Extensionitem 13

Solid Back-up

Ring 125item 309

O-Ring 125item 213

26.ThreadJ-Slot Housing Extension intoJ-Slot External Housing.



27.Perform the Shift Mechanism Pressure Test next by following the procedures in the Testingin the Shop section of this manual.

28.ThreadBurst Disk Replacement CrossoverintoJ-Slot Housing Extension.



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Bullnose Nozzle

1. Install O-Ring 125 ontoRear Jetting Crossover.

Rear Jetting Crossoveritem 15

O-Ring 125

item 213

2. Install three O-Ring 902 onto Pump Oil Plug.

Pump Oil

Plugitem 256

O-Ring 902item 257

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3. Thread three ofPump Oil Plug intoRear Jetting Crossover.Note: Apply Permatex thread sealant to plug threads. Use 5/32" Allan wrench to tighten

plugs.

Pump Oil Plugitem 256Rear Jetting Crossover

item 15

Pump Oil Plugitem 256


4. Install O-Ring 010 intoRear Jetting Crossover.

O-Ring 010item 200


5. Thread the appropriateHalf Dog Orifice intoRear Jetting Crossover.Note: Use Permatex thread sealant onHalf Dog Orifice threads. The most commonly usedHalf Dog Orifice is 0.045.



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6. ThreadRear Jetting Crossoverinto place.Note: If Shift Mechanism Option, then thread theRear Jetting Crossoveronto theJ-SlotExternal Housing.



If using Sand-Vac LockoutorWell-Vac LockoutOption, then thread theRear Jetting

Crossoveronto theBurst Disc Replacement Crossover.

Burst Disc Replacement Crossoveritem 19


7. For theBullnose Nozzle for Memory Gauge option, skip the next two steps and go to the nextsection.

8. Thread two of the appropriate Swirl Nozzle into the 1-3/4 Bullnose Nozzle.Note: Apply Permatex thread sealant to orifice threads. The most commonly usedSwirlNozzle are 0.045 or 0.060.

Swirl Nozzleitem 253

1-3/4 Bullnose Nozzleitem 16


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9. ThreadRear Jetting Crossoverinto 1-3/4 Bullnose Nozzle.


1-3/4 Bullnose Nozzleitem 16

Bullnose with Memory Gauge

1. Thread two of the appropriate Swirl Nozzle into the 1-3/4 Bullnose Nozzle for MemoryGauge.Note: Apply Permatex thread sealant to orifice threads. The most commonly usedSwirlNozzle are 0.045 or 0.060.


1-3/4 Bullnose Nozzle for Memory Gaugeitem 16

Swirl Nozzle

item 253

2. Install O-Ring 116andSolid Back-up Ring 116into 1-3/4 Bullnose Nozzle for MemoryGauge.

1-3/4 Bullnose Nozzle for Memory Gaugeitem 16

O-Ring 116item 208

Solid Back-up

Ring 116item 305

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3. ThreadRear Jetting Crossoverinto 1-3/4 Bullnose Nozzle for Memory Gauge.

Rear Jetting Crossover

item 15

1-3/4 Bullnose Nozzle for Memory Gauge

item 16

4. ThreadMemory Gauge into 1-3/4 Bullnose Nozzle for Memory Gauge.

1-3/4 Bullnose Nozzle for

Memory Gaugeitem 16

Memory Gaugeitem 41

Roll-on to Concentric Coil Connection (CCT)For proper tool function follow all dimensions and procedures exactly for connecting roll-onconnectors to the coiled tubing.

2 x 1 (5.08 cm x 2.54 cm) Concentric Coil Connection (CCT)Connect the 2 (5.08 cm) CT Roll-on Connectorbefore the 1 (2.54 cm)Roll-on Connector.

Outer Concentric Coil Connection (2" CCT)

1. Prepare tubing by cutting so that exactly 20-1/8 (51.1 cm) of 1 (2.54 cm) tubing is exposedfrom the end of the 2" (5.08 cm) tubing. Straighten the inner coiled tubing to make assembly

easier.Note: There is 3/8" (1 cm) tolerance either way on the 1" (2.54 cm) tube but being precise is

better.

2. De-burr tubing.

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3. Install four sets of O-Rings and Back-up Rings (O-Ring 128andSolid Back-up Ring 128form a set) onto CT Roll-on Connector.

O-Ring 128item 216


O-Ring 128item 216


O-Ring 128

item 216Solid Back-up Ring 128item 312

O-Ring 128

item 216Solid Back-up Ring 128item 312

CT Roll-on Connectoritem 1

4. Apply lubricant to O-Rings to aid inserting connector into coiled tubing.

5. Push into 2" Concentric Coiled Tubing, the CT Roll-on Connectoruntil tubing contacts theshoulder of the connector.

2" Concentric Coiled Tubing(CCT)


Non-standard use of Roll-on crimper tool follows.

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6. First crimp segment: Mark a line on the coiled tubing at 3/8" (1 cm) measured fromwhere the tubing meets the connector. This will be the center of the roll-on depression. Don'tcrimp yet!

7. Mark one area on the coiled tubing that should not be crimped.This area is over top of one anti-rotation stop on the connector. When the connector is inside

the coiled tubing, you need to reference one small hole drilled in the side of the connector tofind the position of one anti-rotation stop.

First crimp segment anti-rotation area:

Refer to the marker hole near the end of the coiled tubing. Mark a length of3/8" (1 cm) each side of the marker hole at the first crimp segment position.

Avoid pinching tubing against the anti-rotation stop. Crimp an arc thatbegins 3/8" (1 cm) from the connector marker hole near the coiled tubing end. If you makethe mistake of crimping 360 degrees, the coiled tubing will be cut.

8. Crimp #1: Roll-on the first crimp segment with the Crimper Wheel. CAREFUL! Rememberthere is an anti- rotation stop on this first crimp.

9. Second crimp segment: Mark a line next to the first crimp segment, at 1-1/8" (2.8 cm)from tubing end. This will be the center of the roll-on depression.

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10.Crimp #2: Roll-on the second crimp segment with the Crimper Wheel. This second crimpsegment has no stops so you can roll-on the tubing completely around the connector.

11.Third crimp segment:Mark a line next to the second segment, at 1-7/8" (4.8 cm) fromtubing end.

12.Crimp #3: Roll-on the third crimp segment with the Crimper Wheel. This third crimpsegment has no stops so you can roll-on the tubing completely around the connector.

13.Fourth crimp segment:Mark a line next to the third segment, at 2-5/8" (6.7 cm) fromtubing end.

14.Crimp #4: Roll-on the fourth crimp segment with the Crimper Wheel. This fourth crimpsegment has no stops so you can roll-on the tubing completely around the connector.

Inner Concentric Coil Connection (1" CCT)

1. De-burr tubing.

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2. Install six sets of O-Rings and Back-up Rings (O-Ring 114 andSolid Back-up Ring 114 forma set) ontoRoll-on Connector.

O-Ring

114item 206

Solid

Back-up

Ring 114item 303

O-Ring

114item 206

Solid

Back-up

Ring 114item 303

O-Ring

114item 206

Solid

Back-up

Ring 114item 303

O-Ring

114item 206

Solid

Back-up

Ring 114item 303

O-Ring

114item 206

Solid

Back-up

Ring 114item 303

O-Ring

114item 206

Solid

Back-up

Ring 114item 303

Roll-on Connectoritem 23

3. Apply lubricant to O-rings to aid inserting connector into coiled tubing.

4. Push into 1" Concentric Coiled Tubing, theRoll-on Connectoruntil tubing contacts theshoulder of the connector.

1" Concentric Coiled Tubing

(CCT)


Non-standard use of Roll-on crimper tool follows.

5. First crimp segment: Mark a line on the coiled tubing at 3/8" (1 cm) measured fromwhere the tubing meets the connector. This will be the center of the roll-on depression. Don't

crimp yet!

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6. Mark one area on the coiled tubing that should not be crimped.This area is over top of one anti-rotation stop on the connector. When the connector is inside

the coiled tubing, you need to reference one small hole drilled in the side of the connector tofind the position of the anti-rotation stop.

First crimp segment anti-rotation area:

Refer to the marker hole near the end of the coiled tubing. Mark a length of1/4" (6 mm) each side of the marker hole at the first crimp segment position.

Avoid pinching tubing against the anti-rotation stop. Crimp an arc that

begins 1/4" from the connector marker hole near the coiled tubing end. If you make themistake of crimping 360 degrees, the coiled tubing will be cut.

7. Crimp #1: Roll-on the first crimp segment with the Crimper Wheel. CAREFUL! Rememberthere is an anti- rotation stop on this first crimp.

8. Second crimp segment: Mark a linenext to the first segment, at 1-1/8" (2.8 cm) fromtubing end. This will be the center of the roll-on depression.

9. Crimp #2: Roll-on the second crimp segment with the Crimper Wheel. This second crimpsegment has no stops so you can roll-on the tubing completely around the connector.

10.Third crimp segment:Mark a linenext to the second segment, at 1-7/8" (4.8 cm) fromtubing end.

11.Crimp #3: Roll-on the third crimp segment with the Crimper Wheel. This third crimpsegment has no stops so you can roll-on the tubing completely around the connector.

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12.Fourth crimp segment:Mark a line next to the third segment, at 2-5/8" (6.7 cm) fromtubing end.

13.Crimp #4: Roll-on the fourth crimp segment with the Crimper Wheel. This fourth crimpsegment has no stops so you can roll-on the tubing completely around the connector.

Loading and Transporting Concentric Coiled

Tubing The Injector Loading Gear assembly is used to load the CCT through the injector, and totransport CCT between sites without connecting the tool.

The Injector Loading Gear assembly is fitted with a Snake Grapple Rope Socket. The SnakeGrapple Rope Socketenables a winch cable to be connected to aid in pulling the CCT overthe gooseneck and through the injector.

Correct positioning of the inner string of tubing is imperative for a proper seal. Thus, theInjector Loading Gear assembly is important for preventing any inner string movement.Also, the Snake Tube can be bent to suit the radius of the gooseneck to further aid in loading

the CCT.

See the Appendix section in this manual for the injector loading assembly drawing.

Injector Loading Gear Assembly

1. Install two ofO-Ring 128onto the ends ofSnake Tube.

Snake Tubeitem 500

O-Ring 128item 215

O-Ring 128item 215

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2. ThreadSnake Tube ontoRoll-on Connector

CT Roll-on

Connectoritem 1

Snake Tube

item 500

Roll-on

Connectoritem 23

3. ThreadSnake Assembly NutontoRoll-on Connector

Snake Tubeitem 500

Roll-on

Connectoritem 23

Snake Assembly Nutitem 503

4. ThreadSnake Crossoveronto Snake Tube.

Snake Tubeitem 500

Snake Crossoveritem 501

5. ThreadSnake Grapple Rope Socketonto Snake Crossover.

Snake Crossoveritem 501

Snake Grapple Rope Socketitem 502

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6. ThreadSet Screw 5/16 - 18 UNC x 3/8 into Snake Grapple Rope Socket.

Set Screw 5/16" - 18 UNC x 3/8"item 254

Snake Grapple Rope Socketitem 502

Assembly Shear Sub-Assembly

Installing Shear Rings

1. Install O-Ring 131 andSolid Back-up Ring 131 onto down hole end ofUpper Crossover.

Upper Crossoveritem 4

O-Ring 131item 217

Solid Back-up

Ring 131item 313

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2. Install two sets of O-Rings and Back-up Rings (O-Ring 129 andSolid Back-up Ring 129 forma set) into Upper Crossover.


Solid Back-

up Ring 129item 312

O-Ring 129item 216

Solid Back-

up Ring 129item 312

O-Ring 129item 216

3. Insert Shear Ring and Nogo Retainerinto Upper Crossover.

Shear Ring and Nogo Retaineritem 20


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4. Use CIRCA Job Design to determine the appropriate Shear Ring. Position either two ofShearRing (21,000 lbs) orShear Ring (16,000 lbs) onto the Shear Ring and Nogo Retainer.

Note: For acidic environments use the brass Shear Ring, otherwise use the aluminum ShearRings.

Shear Ring (21, 000 lbs)item 21



or




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5. ThreadShear Ring and Nogo Retainerinto Shear Ring Collar.

Shear Ring Collaritem 3


6. SlideNogo Ring onto Shear Ring and Nogo Retainer.

Nogo Ringitem 2


7. Install O-Ring 128andSolid Back-up Ring 128onto up hole end ofShear Ring and NogoRetainer.


O-Ring 128item 215

Solid Back-up

Ring 128item 311

8. ThreadShear Ring and Nogo Retainerinto CT Roll-on Connector.



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9. ThreadRoll-on ConnectorintoRoll-on Spacer.Note: Do not torque down.


Roll-on Spaceritem 22

10.Install two ofO-Ring 113 onto theRoll-on Spacer Locknut.

Roll-on Spacer Locknutitem 24

O-Ring 113item 205

O-Ring 113item 205

11.ThreadRoll-on ConnectorintoRoll-on Spacer Locknut.Note: Tighten nuts against each other.



12.Install two ofO-Ring 132 intoRoll-on and Filter Housing at the base of threads.

O-Ring 132item 218


O-Ring 132item 218

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13.SlideRoll-on Spacer LocknutintoRoll-on and Filter Housing .



14.ThreadRoll-on and Filter Housing onto Upper Crossover.

Upper Crossover

item 4

Roll-on and Filter Housing

item 5

15.Thread the assembled tool intoRoll-on and Filter Housing.


Assembled tool

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Disassembly

Disassembly Shear Sub-Assembly

1. UnthreadPin To Pin CrossoverfromRoll-on and Filter Housing.



2. UnthreadRoll-on and Filter Housing from Upper Crossover.



3. SlideRoll-on Spacer LocknutfromRoll-on and Filter Housing.



4. Remove two ofO-Ring 132 from theRoll-on and Filter Housing.

O-Ring 132item 218


O-Ring 132item 218

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5. UnthreadRoll-on Connectorfrom theRoll-on Spacer Locknut.



6. Remove two ofO-Ring 113 from theRoll-on Spacer Locknut.


O-Ring 113item 205

O-Ring 113item 205

7. UnthreadRoll-on Connectorfrom theRoll-on Spacer.


Roll-on Spaceritem 22

Removing Shear Rings

1. UnthreadShear Ring and Nogo Retainerfrom CT Roll-on Connector.



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2. Remove O-Ring 128andSolid Back-up Ring 128from up hole end of the Shear Ring andNogo Retainer.


O-Ring 128item 215

Solid Back-up

Ring 128item 311

3. SlideNogo Ring from the Shear Ring and Nogo Retainer.

Nogo Ringitem 2


4. UnthreadShear Ring and Nogo Retainerfrom the Shear Ring Collar.

Shear Ring Collaritem 3


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5. Remove either two ofShear Ring (21,000 lbs) orShear Ring (16,000 lbs) from the ShearRing and Nogo Retainer.







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6. Remove Shear Ring and Nogo Retainerfrom the Upper Crossover.



7. Remove two sets of O-Rings and Back-up Rings (O-Ring 129 andSolid Back-up Ring 129form a set) from inside the Upper Crossover.

Upper Crossover

item 4

Solid Back-

up Ring 129item 312

O-Ring 129

item 216

Solid Back-

up Ring 129item 312

O-Ring 129

item 216

8. Remove O-Ring 131 andSolid Back-up Ring 131 from down hole end of the UpperCrossover.


O-Ring 131item 217

Solid Back-up

Ring 131item 313

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Bullnose Nozzle

Bullnose Nozzle with Memory Gauge

1. UnthreadMemory Gauge fromBullnose Nozzle.

Bullnose Nozzleitem 16

Memory Gaugeitem 41

2. UnthreadRear Jetting CrossoverfromBullnose Nozzle.



3. Remove O-Ring 116andSolid Back-up Ring 116fromBullnose Nozzle.


O-Ring 116item 208

Solid Back-up

Ring 116item 305

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4. Unthread two of the Swirl Nozzle from theBullnose Nozzle.




5.

Go to the next section but skip the first two steps.

Bullnose Nozzle Without Memory Gauge

1. UnthreadRear Jetting CrossoverfromBullnose Nozzle.



2. Unthread two of the Swirl Nozzle from theBullnose Nozzle.




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3. UnthreadRear Jetting Crossover.Note: If Shift Mechanism Option, then unthread theRear Jetting Crossover from theJ-SlotExternal Housing.



If using Sand-Vac LockoutorWell-Vac LockoutOption, then unthread theRear Jetting

Crossoverfrom theBurst Disc Replacement Crossover.

Burst Disc Replacement Crossoveritem 19


4. UnthreadHalf Dog Orifice fromRear Jetting Crossover.



5. Remove O-Ring 010 fromRear Jetting Crossover.

O-Ring 010item 200


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6. Unthread three ofPump Oil Plug fromRear Jetting Crossover.Note: Use 5/32" Allan wrench to loosen plugs.





7. Remove three O-Ring 902 from Pump Oil Plug.

Pump Oil

Plugitem 256

O-Ring 902item 257

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8. Remove O-Ring 125 fromRear Jetting Crossover.


O-Ring 125item 213

Options

Well-Vac Lockout Option

1. Remove Well-Vac LockoutfromBurst Disk Replacement Crossover.



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2. Remove O-Ring 122 andSolid Back-up Ring 122 from Well-Vac Lockout.


O-Ring 122item 211

Solid Back-

up Ring 122item 308

Sand-Vac Lockout Option

1. Remove Sand-Vac LockoutfromBurst Disk Replacement Crossover.



2. Unthread theHalf Dog Orifice from uphole end ofSand-Vac Lockout.



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3. Remove O-Ring 010 from uphole end ofSand-Vac Lockout.

O-Ring 010item 200


4. Remove O-Ring 122 andSolid Back-up Ring 122 from down hole end ofSand-Vac Lockout


O-Ring 122item 211

Solid Back-up

Ring 122item 308

Shift Mechanism Option

Note: The Shift Mechanism Assembly is NOT a field-serviceable item. Return this item tothe service centre for servicing and rebuilding. Do not attempt to service this item without

appropriate supervision and/or training.

1. UnthreadBurst Disk Replac

well-vac v.2 2-18

Documents