Well-Vac v.2 2-18

Well-Vac v.
2
Service Manual (2-1/8")
February 15, 2007
This publication is the property of BJ Services Company and may not be reproduced or translated without prior written consent from the BJ Technical Publication Department, Calgary, Canada.
Read Manual Before Servicing Tool

Please read and understand this service manual with all safety instructions before assembling 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 to another location. Move forward through an assembly or disassembly section because warnings 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 a successfully completed job; to prevent work stoppage due to tool breakdown; and to maximize tool part life. Version Number Updated 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 one General Assembly drawing in the manual. Look to each drawing for the version number.) Copyright Date Updates to a manual are indicated by a new copyright date. Use the manual with the most current 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 a different design have been introduced, then the version of the tool has changed and the original 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 If the copyright date in the database is newer than the copyright date on the manual in hand, then replace the outdated manual with the updated manual. Print an Original - Do Not Photocopy Print 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 not avoided, 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 not avoided, could result in death or serious injury.
Service Manual Conventions

The illustrations below simply show the assembly/disassembly conventions for this manual and 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 be referenced on the General Assembly drawing in the appendix of this manual.) Uphole end is always shown on the left in a photo.
Upper Filter Spacer

item 26
Filter Tube
item 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.
Diffuser
item 30
O-Ring 213
item 217
O-Ring 209
item 216
Quality Control
Update the QC (Quality Control) Schedule with the date and description of service. There are 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 Requirements

1. Remove and discard all O-rings. 2. Use parmalee wrenches (not a vice or pipe wrench) to disassemble the tool.
Essential Assembly Requirements

1. 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 to the surface.
This page is intentionally blank.
Table of Contents
Overview .......................................................................................... 1
Application ........................................................................................................ 1 Equipment Requirements ................................................................................. 2 Surface Equipment ........................................................................................ 3 Site Equipment .............................................................................................. 4
Specifications .................................................................................. 5 How it works .................................................................................... 7 Operational Mode ............................................................................ 9

How Mode Switching Occurs ........................................................................... 9 Determining Mode Setting .............................................................................. 10 Sand Cleanout in Vertical Wells ..................................................................... 11
BHA / Cleanout Operation ............................................................ 13

Chemicals ........................................................................................................ 13 Surface Tests................................................................................................... 13 Run-in-Hole Procedure ................................................................................... 14 Sand Removal Mode (Sand-Vac mode) ........................................................ 14 Fluid Removal Mode (Well-Vac mode) ........................................................... 15 Stuck-in-hole procedure ................................................................................. 16
Testing ........................................................................................... 19
Testing in the Shop ......................................................................................... 19 Filter Assembly, Fluid Flow Guide and Nozzle Pressure Tests .................... 19 Shift Mechanism Pressure Test ................................................................... 21 Testing in the Field.......................................................................................... 22 Coil Connection Pressure Test .................................................................... 23 Surface Test of Tool Function...................................................................... 25
Assembly ....................................................................................... 27
Tool Assembly................................................................................................. 27 Power Nozzle .............................................................................................. 33 Nozzle Calibration ....................................................................................... 35 Options ............................................................................................................ 39 Sand-Vac Lockout Option............................................................................ 39 Well-Vac Lockout Option ............................................................................. 40 Shift Mechanism Option .............................................................................. 41 Bullnose Nozzle............................................................................................... 52 Roll-on to Concentric Coil Connection (CCT) ............................................... 56 2 x 1 (5.08 cm x 2.54 cm) Concentric Coil Connection (CCT) ................... 56 Loading and Transporting Concentric Coiled Tubing .................................. 62 Injector Loading Gear Assembly.................................................................. 62 Assembly Shear Sub-Assembly.................................................................. 64 Installing Shear Rings.................................................................................. 64
Disassembly .................................................................................. 71
Disassembly Shear Sub-Assembly............................................................. 71 Removing Shear Rings................................................................................ 72
Well-Vac v.2 Service Manual (2-1/8")
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Bullnose Nozzle............................................................................................... 76 Options ............................................................................................................ 80 Well-Vac Lockout Option ............................................................................. 80 Sand-Vac Lockout Option............................................................................ 81 Shift Mechanism Option .............................................................................. 82 Tool Disassembly............................................................................................ 91 Power Nozzle .............................................................................................. 96
Troubleshooting .......................................................................... 103 Appendix...................................................................................... 105 Parts Kit Drawings

General Assembly Fishing 1.5 - .75 Concentric Tubing Surface Connector 1.5 1 Concentric Tubing Surface Connector 2 1 Concentric Tubing Surface Connector Tubing Surface Connector Fitting Weld
Welding Information
Welding Procedure Specification Procedure Qualification Record (PQR)
Table of Item Numbers
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Overview
The 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 process incorporates 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 is diverted to nozzles at the front of the tool to fluidize the sand. The remaining fluid passes through 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 mode without external jets
Application
The 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, a constant 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 annular velocities 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 the fluid 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 bottom of 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 has taken place behind the liner during the wells production. This can cause the formation to have 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 to the intake ports for transport to surface.
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Natural Sorting / Bridging Influx / Sloughing
Slotted Liner
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 drilled wells and to aid in new well production from all zones.
Equipment Requirements
The following equipment is required: An additional rotating joint. (The original joint fitted to the drum for the power fluid stream should continue to serve this purpose). The new joint is required to handle the return 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 size and 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 the CCT Surface Connector. Details for this connecting pipe must be determined locally after selecting a reel. Reel size and tubing length dependent on the well profile.
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Surface Equipment
Surface 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
Top-filling
Legend:
FM
Crane Truck Wellhead, Injector & Support Structure
Flow Meter Pressure Transducer High Pressure Filter
P
HP F
Pressure Truck
FM
Return Line
HP F
FM
Dual Compartment Rig Tank
Sand-Vac Pumper with Filter System CCT Reel Unit
Feed Line
400 bbl Tanks

Figure 3 Well-Vac Site Equipment Schematic
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Specifications
IMPERIAL
Overall length 76 - 91
METRIC
1.9 m 2.3 m
Outside diameter
2-1/8 5 F
54.0 mm -15 C
Minimum operating temperature
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 Maximum internal tool pressure Power fluid Annulus Return Aluminum rings no holes Acid soluble Brass ring no holes Acid resistant Aluminum rings 8 holes Acid soluble Brass ring 8 holes Acid resistant
75 lbs 10,000 psi 6,800 psi 21,000 lbs
34 kg 68.9 MPa 46.9 MPa 9,341 daN
Tensile Pull to Shear Note: Tool pressure reduces Pull to Shear by approximately 15,000 lbs at maximum internal tool press
16,000 lbs
7,117 daN
Minimum wellbore diameter
2.188"
55.6 mm
Concentric Coiled Tubing sizes available O-Rings
2" x 1"
5.08 cm x 2.54 cm
Viton 75 duro Grease/lubricants - CV 500 Joint Grease - White Lubriplate
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How it works
The Well-Vac system is based on proven jet pump principles. Modified and patented for use on 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 in through the intake ports. The Well-Vac was designed to provide continuous sand removal and cleaning with minimum well disturbance.
Intake Ports (fluid and wellbore material)
High Velocity
High Pressure
Throat Nozzle
Low Pressure
Low 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 a diffuser, 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 high enough to transport sand.
Figure 5 - CCT / Well-Vac
TM
Flow Diagram
The Well-Vac has a 2-1/8" (5.40 cm) OD that allows it to be used in liner or tubular sizes 2-3/16" (5.56 cm) or larger.
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Operational Mode
The Well-Vac operates in two modes - Well-Vac or Sand-Vac - with various Power Nozzles installed. In Sand-Vac mode, the tool is designed to clean out fill while running in the hole and pulling out of the hole. This is accomplished by having both forward and reverse swirl nozzles. The Sand-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 fully aware of the tool's mode setting. Running the 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 Occurs

Switching 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, the J-Slot Shaft moves 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 a position where the swirl jets can be activated. Once the flow is diverted to these jets, a change 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 below approximately 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 to below 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 surface test 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 to obtain 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: External jets: J-slot shaft:
WELL-VAC off short stroke
SAND-VAC On long stroke
When operating the Well-Vac 2-1/8" in deep wells, take special care when shifting modes. A deep well may provide enough hydrostatic pressure in the tubing to inhibit 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 pump eliminates pump pressure, and closing the reel valves keeps water from siphoning from surface and maintaining hydrostatic head. Even though the operator will see the pressure quickly 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 is continued, 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 surface unless the valve is closed between the tank and the coiled tubing. Failure to close the valve at surface will result in the tool remaining under full hydrostatic pressure until the tank is completely drained.
Determining Mode Setting

To 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 (3000 ft) low pressure springs] or [1850 metres (6000 ft) high pressure springs], it may be necessary 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 by CIRCA for the Well-Vac mode. 3. After the coiled tubing is full, bring the tool to full operational pressure and note the flow rate 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 lower flow rate is the Well-Vac flow rate (Swirl Nozzles not activated) the higher flow 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 values alone. 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 proper mode 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 Wells

The Well-Vac now performs sand cleanout operations in vertical gas or oil wells but this type of sand cleanout offers unique challenges over a horizontal sand cleanout - primarily controlling RIH speeds and tool depth in fill. Controlling RIH speeds Controlling RIH speed is critical for preventing excessive Throat and Nozzle erosion. Since the wellbore is 100% full of sand in the cleanout region, the tool can draw in excessive sand percentages of the wellbore fluid/sand slurry. Increasing the RIH speed beyond what the tool can safely remove reduces the fluidization capacity 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 on the Throat face and Nozzle tip. If left uncorrected this erosion might force a trip to surface to replace these parts prematurely. hydrostatic pressure of the return fluid column exceeding the pressure generated by the jet pump causing returns to decrease or stop completely. The CCT annulus could become plugged, requiring a partial trip to surface.
Controlling Tool Depth in Fill Controlling the tool depth under the fill column is important for preventing a stuck-in-hole condition. 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 extremely risky method of tool operation. If the jetting nozzles shut down for any reason and cannot be restarted, the possibility of becoming 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 of jetting nozzle shutdown or failure. Being diligent about RIH rates and the tool depth under fill aids significantly in performing a successful sand cleanout in any vertical well.
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BHA / Cleanout Operation

Chemicals
A friction reducer (i.e. FRW-14) is normally used to reduce the fluid friction in the power and return sides of the CCT. Concentrations generally range from 0.75 to 1 gal/1000 gal (0.75 to 1 L/1000 litres). A dispersant is often added to the water (power fluid) to reduce viscosity of the return flow when 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 the viscosity 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. A lab 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 (0.5 L/1000 litres) typically used.
For light or medium density oil wells perform compatibility tests to ensure an oil external emulsion will not form with mixing.
Surface Tests
Perform 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 Shop section of this manual. pressure test Roll-on Connectors using the proper connections to ensure there are no leaks. function test the tool on surface before RIH to ensure it is shifting properly, the swirl jets are functioning properly and there are no leaks in Well-Vac mode.
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Run-in-Hole Procedure
To conserve power fluid, the Well-Vac is typically run in hole at a reduced pump rate from that predicted by CIRCA, or no pump rate at all with surface valving closed. Pumping can be in either Sand-Vac or Well-Vac modes. At a certain point above the cleanout depth or suspected sand top, stop the CCT and set the operational 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 well parameters. 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 be established before proceeding with the cleanout. Accurate return flow measurements are difficult to impossible when dealing with gasified return fluid. A safe RIH rate through production tubing sections depends on CCT size and completion restrictions. 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 the chosen 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 are produced from the well, Throat erosion may reduce performance or suction rate to the point that 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 sand concentration 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 may indicate 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 be correlated with the sand concentrations. Monitor injection pressure closely, along with the injection and return rates, to ensure the tool is functioning properly. A sudden drop in injection pressure (normally accompanied by a drop 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 a horizontal 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 be conducted. 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 seconds to 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 mud damage 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 concentrations are 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 from 3.3 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 being removed 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 procedure
If the CCT becomes stuck in the wellbore, there is a built-in release system in the Well-Vac that can be used. The release system is the last option in the event that the CCT becomes stuck. 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 the pipe 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 daN or 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 string weight. 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 20-50 meters (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 soak around the tool. This will work provided the tool is still very close to the build section of the 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 as dictated by completion size. 6. The returns to the rig tank can be closed and fluid can be pumped down both inner and outer strings. This will give a high rate surge down hole and may dislodge the coiled tubing. 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 with nitrogen 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 out of hole.
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10. In a pipe stuck situation, displace the complete coiled tubing to nitrogen gas. This places the pipe in a PIPE LITE situation. Continue to work the pipe. Try this before attempting the overpull to release the tool. 11. A gel pill can be spotted down around the tool and allowed to sit for 15 minutes before continuing to work the pipe. The gel can also be foamed as another method of freeing stuck coiled tubing. If all of the above measures fail, the Well-Vac may have to be released off the tubing. 1. The Well-Vac has built in Shear Rings that allow the CCT to be pulled off the tool. The Shear 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 entire tool 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 operating pressures applied to it, the pull to shear reduces by 14,700 lbs (6500 daN).Continue to pump 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 tool stuck situation. 3. If the tool will not shear, 500 liters (3.14 bbl) of 15% HCl can be spotted around the tool and allowed to soak for 30 minutes to acidize the aluminum shear rings. If the brass shear rings are in place, this method will not help to release the tool. Again, attempt an overpull to release the tool. In all cases, perform CIRCA ANALYSIS and notify the appropriate personnel.
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Testing
Specific 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 Shop

If the Well-Vac is stored for any duration following this test, use an oil/inhibited water emulsion in the pump for the test.
Filter Assembly, Fluid Flow Guide and Nozzle Pressure Tests

Pressure test the assembly to determine if there are any leaks. Testing Procedure
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Pressure Testing Layout During this test the Blank 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 the Blank Power Nozzle instead of an operational Power Nozzle. 2. Prepare Test Cap by plugging NPT hole with a NPT plug and threading onto the Burst 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 inside Test 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. Thread Test 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. DO NOT 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 the Blank Power Nozzle with the operational Power Nozzle in the tool, and follow the calibration procedures as outlined in the Assembly section of this manual.
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Shift Mechanism Pressure Test

Test 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 when performing 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 is not the case you won't be able to pressure up the shifting mechanism and it will have to be removed and placed in a press to cycle the J-Slot into the correct position. Refer to the section, Shift Mechanism Function Test, in this manual for instructions on how to achieve this. Shift Mechanism Testing Procedure
J-Slot External Housing (item 14)
O-ring #125 (item 213)
J-Slot Housing Extension (item 13)
Bullnose Assembly
Test Cap (item T8) 1/4" NPT Extension
Fitting
Shift Mechanism Testing Layout 1. Complete the tool assembly procedures from steps 1 to 26 in the Shift Mechanism Option section of this manual. 2. Prepare Test Cap with O-Ring 125 and fittings needed to connect it to the hand pump. 3. Thread Test Cap into J-Slot Housing Extension.
Page: 21
4. Cover the end of the J-Slot External Housing with some paper towel to prevent fluid spill. 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 (55.2 MPa). 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) or 3000 psi (low pressure springs), the J-Slot is in Sand-Vac mode. Relieve pressure, and remove the Test Cap and the J-Slot Housing Extension. Drain fluid and perform the Shift Mechanism Function Test as described in the assembly section of this manual ensuring that 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. Reassemble 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) or 3000 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 hand pump. Fluid should also have leaked out the front of the J-Slot External Housing and into the paper towel. 14. Relieve residual pressure, drain fluid from the tool, and remove Test Cap.
Testing in the Field

Take precautions to avoid plugging swirl jet orifice with debris. Tool function will be severely compromised if this occurs. Pig or pickle the coiled tubing prior to connecting the Well-Vac tool to avoid introducing debris 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 connectors attached.
Page: 22
Fill coiled tubing with service fluid prior to testing.
Coil Connection Pressure Test

Test the Coil Connection pressure in the field to fully pressure both roll-on connectors and coiled 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 atmosphere so 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 as described in Installing Shear Rings onto the coiled tubing roll-on connectors. 2. Thread the extra Pin To Pin Crossover onto Roll-on and Filter Housing. 3. Thread Test Cap onto Pin To Pin Crossover. 4. Fill coil if not already full. 5. Close off return fluid flow.
Page: 23
6. Begin pressurizing the tool, leaks will be obvious as this is now pressurizing the external side of the tool. 7. Pressure coil to a maximum of 6800 psi (46.9 MPa), not any higher. Hold pressure for a moment 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 as described in Installing Shear Rings) onto the coiled tubing roll-on connectors. 2. Thread the extra Pin To Pin Crossover onto Roll-on and Filter Housing. 3. Prepare Test Fixture by plugging the NPT hole with a NPT plug. Install O-Ring 113. 4. Insert Test Fixture into Test Cap. Make sure to leave the NPT hole open so that any leaks will be obvious. 5. Thread Test Cap onto Pin To Pin Crossover, ensuring that the Test Fixture is properly seated into Pin To Pin Crossover.
Page: 24
6. Begin pressurizing up the coiled tubing while watching for leaks from the hole in the Test Cap. 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 and Test Fixture from tool.
Surface Test of Tool Function

Surface 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 injury could 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. Keep all 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 previous tests. 2. Remove the extra Pin To Pin Crossover from Roll-on and Filter Housing. 3. Connect the down hole tool assembly to Roll-on Housing. 4. Place down hole end of tool in a barrel so that the fluid from the swirl jets will be contained in the barrel. 5. Tool should be in Sand-Vac mode if the proper procedure for the Shifting Mechanism test was followed.
Page: 25
6. Begin to pressure up the tool. As the shifting flow rate approaches, watch for a pressure drop. 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 mode confirm that it shifted at approximately the correct flow rate. 7. Continue to increase flow rate until the maximum flow rate for the appropriate mode is achieved. 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.
Page: 26
Assembly
Apply CV 500 Joint grease to all threads and O-Rings unless otherwise stated.
Tool Assembly
1. Thread Filter Lower NPT Spacer onto Power Fluid Filter. Note: Use Teflon tape on threads.
Power Fluid Filter

item 27
Filter Lower NPT Spacer

item 28
2. Install two of O-Ring 123 onto Filter Lower NPT Spacer. Install two of O-Ring 113 onto end of Filter Lower NPT Spacer.

item 28
O-Ring 123
item 212
O-Ring 123
item 212
O-Ring 113
item 205
O-Ring 113
item 205
3. Install two of O-Ring 113 onto end of Filter Upper Spacer. Install two of O-Ring 123 onto Filter Upper Spacer.
Filter Upper Spacer

item 25
O-Ring 113
item 205
O-Ring 113
item 205
O-Ring 123
item 212
O-Ring 123
item 212
Page: 27
4. Slide Filter Lower NPT Spacer into Filter Tube.
Filter Tube
item 26

item 28
5. Push Filter Upper Spacer onto Filter Tube.
Filter Upper Spacer

item 25
Filter Tube
item 26
6. Install two sets of O-Rings and Back-up Rings (O-Ring 131 and Solid Back-up Ring 131 form a set) onto Pin To Pin Crossover.
Pin To Pin Crossover

item 6
O-Ring 131
item 217
Solid Back-up Ring 131

item 313

item 313
O-Ring 131
item 217
Page: 28
7. Slide Pin To Pin Crossover over Filter Upper Spacer. Note: Notice that the Filter Tube end without wrench flats goes in to the Pin To Pin Crossover.

item 6
Filter Upper Spacer

item 25
8. Install two of O-Ring 132 into the Roll-on and Filter Housing at the base of threads.
O-Ring 132
item 218
Roll-on and Filter Housing

item 5
O-Ring 132
item 218
9. Thread Filter Housing onto the Pin To Pin Crossover.

item 6
Filter Housing
item 7
Page: 29
10. Install O-Ring 131 and Solid Back-up Ring 131 onto the up hole end of Fluid Exchanger . Install three sets of O-Rings and Back-up Rings (O-Ring 129 and Solid Back-up Ring 129 form a set) onto Fluid Exchanger.
Fluid Exchanger
item 8
O-Ring 131
item 217
O-Ring 129
item 216
O-Ring 129
item 216
O-Ring 129
item 216

item 313

item 312

item 312

item 312
11. Thread Roll-on and Filter Housing onto the Fluid Exchanger.

item 5
Fluid Exchanger
item 8
12. Slide Fluid Exchange Tube over Fluid Exchanger.
Fluid Exchanger
item 8
Fluid Exchange Tube

item 9
Page: 30
13. Install O-Ring 210 and Solid Back-up Ring 210 onto the Diffuser. For #4 and larger throats, use the long Diffuser. For #3 and smaller throats, use the short Diffuser.
Diffuser
item 29
O-Ring 210
item 220

item 314
14. Insert O-Ring 207 into down hole end of the Diffuser.
Diffuser
item 29
O-Ring 207
item 219
15. Grease entire Diffuser. Install Diffuser into the Fluid Exchanger.
Fluid Exchanger
item 8
Diffuser
item 29
Page: 31
16. Apply small amount of Locktite 242 to threads and insert the appropriate Throat into Throat Retainer Nut. Note: Use CIRCA Job Design to determine the appropriate Throat.
Throat
item 30
Throat Retainer Nut

item 31
17. Thread Throat Retainer Nut into Fluid Exchanger.
Fluid Exchanger
item 8
Throat Retainer Nut

item 31
18. Install O-Ring 212 and Solid Back-up Ring 212 into up hole end of Sand Intake Crossover. Note: Ensure Back-Up Ring is on the down hole side of the O-Ring groove.
O-Ring 212
item 221

item 315
Sand Intake Crossover

item 10
19. Install O-Ring 118 and Solid Back-up Ring 118 into down hole end of Sand Intake Crossover. Note: Ensure Back-Up Ring is on the uphole side of the O-Ring groove.

item 10

item 306
O-Ring 118
item 209
Page: 32
20. Thread Fluid Exchanger into Sand Intake Crossover.
Fluid Exchanger
item 8

item 10
Power Nozzle
1. Install O-Ring 013 and Solid Back-up Ring 013 into up hole end of Nozzle Retainer Cap.

item 300
O Ring 013
item 201
Nozzle Retainer Cap

item 32
2. Install the appropriate Power Nozzle into the Nozzle Retainer Cap. Note: Use CIRCA Job Design to determine the appropriate Power Nozzle.
Nozzle Retainer Cap

item 32
Power Nozzle
item 33
3. Thread the Nozzle Retainer Cap onto Nozzle Retainer.
Nozzle Retainer Cap

item 32
Nozzle Retainer
item 34
Page: 33
4. Place Nozzle Retainer Cap into Power Nozzle Clamp.
Power Nozzle Clamp

item T1
Nozzle Retainer Cap

item 32
5. Place Power Nozzle Clamp into a vise. Tighten Nozzle Retainer Cap into Nozzle Retainer. Remove Power Nozzle assembly from the vise and Power Nozzle Clamp to continue.
Power Nozzle Clamp

item T1
Nozzle Retainer
item 34
Nozzle Retainer Cap

item 32
Page: 34
Nozzle Calibration
1. Thread in and softly seat Nozzle Retainer into Sand Intake Crossover. Back out Nozzle Retainer to achieve approximately 0.100 spacing (approx. 1.25 turns).

item 10
Nozzle Retainer
item 34
2. Thread Nozzle Retainer Nut onto Nozzle Retainer.
Nozzle Retainer
item 34
Nozzle Retainer Nut

item 250
3. Thread Nozzle Retainer Locknut onto Nozzle Retainer.
Nozzle Retainer
item 34
Nozzle Retainer Locknut

item 251
Page: 35
4. Tighten Nozzle Retainer Nut and Nozzle Retainer Locknut with adjustable wrenches as shown and torque together.
Nozzle Retainer Nut

item 250

item 251
5. Insert Sand Intake Crossover into the appropriate Suction Screen. Note: Use Vertical Screen for wells up to approximately 80 inclination.

item 10
Suction Screen
item 11
Page: 36
6. Install O-Ring 129 and Solid Back-up Ring 129 onto Sand Intake Crossover.

item 10

item 312
O-Ring 129
item 216
7. Thread the Bullnose Crossover onto the Sand Intake Crossover.

item 10
Bullnose Crossover
item 12
8. Slide two sets of O-Rings and Back-up Rings [O-Ring 125 and Solid Back-up Ring 125 form a set] onto either end of the Burst Disk Replacement Crossover.
O-Ring 125
item 213

item 309

item 309
O-Ring 125
item 213
Burst Disk Replacement Crossover

item 19
Page: 37
9. Install Spirlok, 1.188 into uphole end of the Burst Disk Replacement Crossover.
Spirlok, 1.188
item 377

item 19
Spirlok, 1.188
item 377
10. Thread Lee Filter into Filter Spacer.
Lee Filter
item 100
Filter Spacer
item 42
11. Install Filter Spacer into Burst Disk Replacement Crossover.
Lee Filter
item 100
Filter Spacer
item 42
12. Bend up the tab on the Spirlok, 1.188 and slide it into the down hole end groove of the Burst Disk Replacement Crossover.
Spirlok, 1.188
item 377

item 19
Spirlok, 1.188
item 377
Page: 38
13. Thread the Bullnose Crossover onto the Burst Disk Replacement Crossover.
Bullnose Crossover
item 12

item 19
Options
Sand-Vac Lockout Option
1. Slide O-Ring 122 and Solid Back-up Ring 122 onto downhole end of Sand-Vac Lockout.
Sand-Vac Lockout
item 35
O-Ring 122
item 211

item 308
2. Insert O-Ring 010 into uphole end of Sand-Vac Lockout.
O-Ring 010
item 200
Sand-Vac Lockout
item 35
Page: 39
3. Thread the appropriate Half Dog Orifice into uphole end of Sand-Vac Lockout. Note: Use Permatex High Temperature Thread Sealant on Half Dog Orifice threads. Use CIRCA Job Design to determine the appropriate Half Dog Orifice.
Half Dog Orifice

item 36
Sand-Vac Lockout
item 35
4. Insert Sand-Vac Lockout into Burst Disk Replacement Crossover.

item 19
Sand-Vac Lockout
item 35
Well-Vac Lockout Option

1. Slide O-Ring 122 and Solid Back-up Ring 122 onto Well-Vac Lockout.
Well-Vac Lockout
item 35
O-Ring 122
item 211

item 308
Page: 40
2. Insert Well-Vac Lockout into Burst Disk Replacement Crossover.

item 19
Well-Vac Lockout
item 35
Shift Mechanism Option

Note: 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 without appropriate supervision and/or training. Use white Lubriplate grease on the Shift Mechanism Assembly. 1. Install O-Ring 115 and Solid Back-up Ring 115 into up hole end of J-Slot Valve Body.
O-Ring 115
item 207

item 304
J-Slot Valve Body

item 39
2. Seat the smaller HP J-Slot Seal into O-Ring 132 and install into up hole end of J-Slot Valve Body.
HP J-Slot Seal
item 317
O-Ring 132
item 218
J-Slot Valve Body

item 39
Page: 41
3. Install O-Ring 119 and Solid Back-up Ring 119 onto the J-Slot Valve Body.
J-Slot Valve Body

item 39
O-Ring 119
item 210

item 307
4. Install Slydring into the J-Slot Bearing Washer.
Slydring
item 316
J-Slot Bearing Washer

item 38
5. Apply grease to the outside of the J-Slot Bearing Washer and install into the up hole end of the J-Slot Valve Body.

item 38
J-Slot Valve Body

item 39
Page: 42
6. Install Disc Spring onto the J-Slot Shaft in the orientation shown in the accompanying diagram. 61 high pressure Disc Spring, or 65 low pressure Disc Spring. Note: Lubricate J-Slot Shaft with grease before installing Disc Spring.
Disc Spring
item 400
J-Slot Shaft
item 37
Orientation of Disc Spring on J-Slot Shaft 7. Grease and install O-Ring 110 and Solid Back-up Ring 110 onto the J-Slot Shaft.
J-Slot Shaft
item 37
O-Ring 110
item 204

item 302
8. Install Thrust Bearing Washer onto the J-Slot Shaft.
J-Slot Shaft
item 37
Thrust Bearing Washer

item 376
Page: 43
9. Pack Thrust Bearing with grease and install onto J-Slot Shaft.
J-Slot Shaft
item 37
Thrust Bearing
item 325
10. Grease J-Slot Shaft and install into assembled J-Slot Valve Body. Press into place.
J-Slot Shaft
item 37
J-Slot Valve Body

item 39
11. Insert J-Slot End into the J-Slot Valve Body. Tighten using a 5/16" Screwdriver.
J-Slot Valve Body

item 39
J-Slot End
item 40
12. Insert assembled Shift Mechanism into Spring Compressor Housing.
assembled Shift Mechanism
Spring Compressor Housing

item T2
Page: 44
13. Orient slotted end of Spring Compressor End facing down hole, then insert into Spring Compressor Housing.
Spring Compressor End

item T3

item T2
14. Place Spring Compressor Housing with assembled Shift Mechanism into a vise. Note: Tighten Spring Compressor End using a wrench.

item T3

item T2
Page: 45
15. Tighten J-Slot End with a screwdriver.

item T2
J-Slot End
item 40
16. Unthread Spring Compressor End from Spring Compressor Housing. Note: Reverse orientation of Spring Compressor End and thread into Spring Compressor Housing. Tighten using a wrench.

item T3

item T2
Page: 46
17. Further tighten J-Slot End with a screwdriver to ensure tightness.

item T2
J-Slot End
item 40
18. Install two of J-Slot Pin into J-Slot Valve Body. Note: Disc Spring need to be slightly compressed. The J-Slot Shaft may need to be rotated to ensure pins fall into slots.
J-Slot Pin
item 350
J-Slot Valve Body

item 39
J-Slot Pin
item 350
Page: 47
19. Install O-Ring 019 onto J-Slot Valve Body to retain J-Slot Pin. Note: Remove Shift Mechanism assembly from the vise and Spring Compressor Housing to continue.
J-Slot Valve Body

item 39
O-Ring 019
item 203
20. Insert O-Ring 010 into J-Slot Shaft.
O-Ring 010
item 200
J-Slot Shaft
item 37
21. Thread the appropriate Half Dog Orifice into J-Slot Shaft. Use PST on Half Dog Orifice threads. Note: Use CIRCA Job Design to determine the appropriate Half Dog Orifice.
Half Dog Orifice

item 36
J-Slot Shaft
item 37
Page: 48
22. Install O-Ring 125 and Solid Back-up Ring 125 onto J-Slot External Housing.
J-Slot External Housing

item 14

item 309
O-Ring 125
item 213
23. Insert assembled Shift Mechanism into J-Slot External Housing.
Assembled Shift Mechanism

item 14
24. Perform the Shift Mechanism Function Test next.
Page: 49
Shift Mechanism Function Test Observe the following cautions during the function testing procedure: rotation of the J-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 last stroke was a long one). 1. Using a drill press, test that the Shift Mechanism can be successfully compressed into the J-Slot External Housing to the depth shown in the picture below. 2. Pressure test this device.
Drill Press assembled Shift Mechanism J-Slot External Housing

item 14
Page: 50
Shift Mechanism Option Assembly contd 25. Install O-Ring 125 and Solid Back-up Ring 125 onto J-Slot Housing Extension.
J-Slot Housing Extension

item 13

item 309
O-Ring 125
item 213
26. Thread J-Slot Housing Extension into J-Slot External Housing.

item 13

item 14
27. Perform the Shift Mechanism Pressure Test next by following the procedures in the Testing in the Shop section of this manual. 28. Thread Burst Disk Replacement Crossover into J-Slot Housing Extension.

item 19

item 13
Page: 51
Bullnose Nozzle
1. Install O-Ring 125 onto Rear Jetting Crossover.
Rear Jetting Crossover

item 15
O-Ring 125
item 213
2. Install three O-Ring 902 onto Pump Oil Plug.
Pump Oil Plug

item 256
O-Ring 902
item 257
Page: 52
3. Thread three of Pump Oil Plug into Rear Jetting Crossover. Note: Apply Permatex thread sealant to plug threads. Use 5/32" Allan wrench to tighten plugs.
Pump Oil Plug

item 256

item 15
Pump Oil Plug

item 256
Pump Oil Plug

item 256
4. Install O-Ring 010 into Rear Jetting Crossover.
O-Ring 010
item 200

item 15
5. Thread the appropriate Half Dog Orifice into Rear Jetting Crossover. Note: Use Permatex thread sealant on Half Dog Orifice threads. The most commonly used Half Dog Orifice is 0.045.
Half Dog Orifice

item 36

item 15
Page: 53
6. Thread Rear Jetting Crossover into place. Note: If Shift Mechanism Option, then thread the Rear Jetting Crossover onto the J-Slot External Housing.

item 14

item 15
If using Sand-Vac Lockout or Well-Vac Lockout Option, then thread the Rear Jetting Crossover onto the Burst Disc Replacement Crossover.
Burst Disc Replacement Crossover

item 19

item 15
7. For the Bullnose Nozzle for Memory Gauge option, skip the next two steps and go to the next section. 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 used Swirl Nozzle are 0.045 or 0.060.
Swirl Nozzle
item 253
1-3/4 Bullnose Nozzle

item 16
Swirl Nozzle
item 253
Page: 54
9. Thread Rear Jetting Crossover into 1-3/4 Bullnose Nozzle.

item 15
1-3/4 Bullnose Nozzle

item 16
Bullnose with Memory Gauge 1. Thread two of the appropriate Swirl Nozzle into the 1-3/4 Bullnose Nozzle for Memory Gauge. Note: Apply Permatex thread sealant to orifice threads. The most commonly used Swirl Nozzle are 0.045 or 0.060.
Swirl Nozzle
item 253
1-3/4 Bullnose Nozzle for Memory Gauge

item 16
Swirl Nozzle
item 253
2. Install O-Ring 116 and Solid Back-up Ring 116 into 1-3/4 Bullnose Nozzle for Memory Gauge.

item 16
O-Ring 116
item 208

item 305
Page: 55
3. Thread Rear Jetting Crossover into 1-3/4 Bullnose Nozzle for Memory Gauge.

item 15

item 16
4. Thread Memory Gauge into 1-3/4 Bullnose Nozzle for Memory Gauge.

item 16
Memory Gauge
item 41
Roll-on to Concentric Coil Connection (CCT)

For proper tool function follow all dimensions and procedures exactly for connecting roll-on connectors 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 Connector before 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 exposed from 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.
Page: 56
3. Install four sets of O-Rings and Back-up Rings (O-Ring 128 and Solid Back-up Ring 128 form a set) onto CT Roll-on Connector.
O-Ring 128
item 216
O-Ring 128
item 216

item 312

item 312
O-Ring 128
item 216
O-Ring 128
item 216

item 312 item 1

item 312
CT Roll-on Connector
4. Apply lubricant to O-Rings to aid inserting connector into coiled tubing. 5. Push into 2" Concentric Coiled Tubing, the CT Roll-on Connector until tubing contacts the shoulder of the connector.
2" Concentric Coiled Tubing (CCT)
item 1
Non-standard use of Roll-on crimper tool follows.
Page: 57
6. First crimp segment: Mark a line on the coiled tubing at 3/8" (1 cm) measured from where the tubing meets the connector. This will be the center of the roll-on depression. Don't crimp 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 to find 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 of 3/8" (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 that begins 3/8" (1 cm) from the connector marker hole near the coiled tubing end. If you make the 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! Remember there 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.
Page: 58
10. Crimp #2: Roll-on the second crimp segment with the Crimper Wheel. This second crimp segment 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) from tubing end.
12. Crimp #3: Roll-on the third crimp segment with the Crimper Wheel. This third crimp segment 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) from tubing end.
14. Crimp #4: Roll-on the fourth crimp segment with the Crimper Wheel. This fourth crimp segment has no stops so you can roll-on the tubing completely around the connector. Inner Concentric Coil Connection (1" CCT) 1. De-burr tubing.
Page: 59
2. Install six sets of O-Rings and Back-up Rings (O-Ring 114 and Solid Back-up Ring 114 form a set) onto Roll-on Connector.
O-Ring 114
item 206
O-Ring 114
item 206
O-Ring 114
item 206
O-Ring 114
item 206
O-Ring 114
item 206
O-Ring 114
item 206

item 303

item 303

item 303

item 303 item 23

item 303

item 303
Roll-on Connector
3. Apply lubricant to O-rings to aid inserting connector into coiled tubing. 4. Push into 1" Concentric Coiled Tubing, the Roll-on Connector until tubing contacts the shoulder of the connector.
1" Concentric Coiled Tubing (CCT)
Roll-on Connector
item 23
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 from where the tubing meets the connector. This will be the center of the roll-on depression. Don't crimp yet!
Page: 60
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 to find 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 of 1/4" (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 the mistake of crimping 360 degrees, the coiled tubing will be cut. 7. Crimp #1: Roll-on the first crimp segment with the Crimper Wheel. CAREFUL! Remember there is an anti- rotation stop on this first crimp. 8. Second crimp segment: Mark a line next to the first segment, at 1-1/8" (2.8 cm) from tubing 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 crimp segment has no stops so you can roll-on the tubing completely around the connector. 10. Third crimp segment: Mark a line next to the second segment, at 1-7/8" (4.8 cm) from tubing end.
11. Crimp #3: Roll-on the third crimp segment with the Crimper Wheel. This third crimp segment has no stops so you can roll-on the tubing completely around the connector.
Page: 61
12. Fourth crimp segment: Mark a line next to the third segment, at 2-5/8" (6.7 cm) from tubing end.
13. Crimp #4: Roll-on the fourth crimp segment with the Crimper Wheel. This fourth crimp segment 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 to transport CCT between sites without connecting the tool. The Injector Loading Gear assembly is fitted with a Snake Grapple Rope Socket. The Snake Grapple Rope Socket enables a winch cable to be connected to aid in pulling the CCT over the gooseneck and through the injector. Correct positioning of the inner string of tubing is imperative for a proper seal. Thus, the Injector 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 of O-Ring 128 onto the ends of Snake Tube.
Snake Tube
item 500
O-Ring 128
item 215
O-Ring 128
item 215
Page: 62
2. Thread Snake Tube onto Roll-on Connector
item 1
Snake Tube
item 500
Roll-on Connector
item 23
3. Thread Snake Assembly Nut onto Roll-on Connector
Snake Tube
item 500
Roll-on Connector
item 23
Snake Assembly Nut

item 503
4. Thread Snake Crossover onto Snake Tube.
Snake Tube
item 500
Snake Crossover
item 501
5. Thread Snake Grapple Rope Socket onto Snake Crossover.
Snake Crossover
item 501
Snake Grapple Rope Socket

item 502
Page: 63
6. Thread Set 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 Socket

item 502
Assembly Shear Sub-Assembly

Installing Shear Rings
1. Install O-Ring 131 and Solid Back-up Ring 131 onto down hole end of Upper Crossover.
Upper Crossover
item 4
O-Ring 131
item 217

item 313
Page: 64
2. Install two sets of O-Rings and Back-up Rings (O-Ring 129 and Solid Back-up Ring 129 form a set) into Upper Crossover.
Upper Crossover
item 4
Solid Backup Ring 129

item 312
O-Ring 129
item 216

item 312
O-Ring 129
item 216
3. Insert Shear Ring and Nogo Retainer into Upper Crossover.
Shear Ring and Nogo Retainer

item 20
Upper Crossover
item 4
Page: 65
4. Use CIRCA Job Design to determine the appropriate Shear Ring. Position either two of Shear Ring (21,000 lbs) or Shear Ring (16,000 lbs) onto the Shear Ring and Nogo Retainer. Note: For acidic environments use the brass Shear Ring, otherwise use the aluminum Shear Rings.
Shear Ring (21, 000 lbs)

item 21

item 20

item 21
or

item 21

item 20

item 21
Page: 66
5. Thread Shear Ring and Nogo Retainer into Shear Ring Collar.
Shear Ring Collar

item 3

item 20
6. Slide Nogo Ring onto Shear Ring and Nogo Retainer.
Nogo Ring
item 2

item 20
7. Install O-Ring 128 and Solid Back-up Ring 128 onto up hole end of Shear Ring and Nogo Retainer.

item 20
O-Ring 128
item 215

item 311
8. Thread Shear Ring and Nogo Retainer into CT Roll-on Connector.
item 1

item 20
Page: 67
9. Thread Roll-on Connector into Roll-on Spacer. Note: Do not torque down.
Roll-on Connector
item 23
Roll-on Spacer
item 22
10. Install two of O-Ring 113 onto the Roll-on Spacer Locknut.
Roll-on Spacer Locknut

item 24
O-Ring 113
item 205
O-Ring 113
item 205
11. Thread Roll-on Connector into Roll-on Spacer Locknut. Note: Tighten nuts against each other.
Roll-on Connector
item 23

item 24
12. Install two of O-Ring 132 into Roll-on and Filter Housing at the base of threads.
O-Ring 132
item 218

item 5
O-Ring 132
item 218
Page: 68
13. Slide Roll-on Spacer Locknut into Roll-on and Filter Housing .

item 24

item 5
14. Thread Roll-on and Filter Housing onto Upper Crossover.
Upper Crossover
item 4

item 5
15. Thread the assembled tool into Roll-on and Filter Housing.

item 5
Assembled tool
Page: 69
Page: 70
Disassembly
Disassembly Shear Sub-Assembly
1. Unthread Pin To Pin Crossover from Roll-on and Filter Housing.

item 5

item 6
2. Unthread Roll-on and Filter Housing from Upper Crossover.
Upper Crossover
item 4

item 5
3. Slide Roll-on Spacer Locknut from Roll-on and Filter Housing.

item 24

item 5
4. Remove two of O-Ring 132 from the Roll-on and Filter Housing.
O-Ring 132
item 218

item 5
O-Ring 132
item 218
Page: 71
5. Unthread Roll-on Connector from the Roll-on Spacer Locknut.
Roll-on Connector
item 23

item 24
6. Remove two of O-Ring 113 from the Roll-on Spacer Locknut.

item 24
O-Ring 113
item 205
O-Ring 113
item 205
7. Unthread Roll-on Connector from the Roll-on Spacer.
Roll-on Connector
item 23
Roll-on Spacer
item 22
Removing Shear Rings

1. Unthread Shear Ring and Nogo Retainer from CT Roll-on Connector.
item 1

item 20
Page: 72
2. Remove O-Ring 128 and Solid Back-up Ring 128 from up hole end of the Shear Ring and Nogo Retainer.

item 20
O-Ring 128
item 215

item 311
3. Slide Nogo Ring from the Shear Ring and Nogo Retainer.
Nogo Ring
item 2

item 20
4. Unthread Shear Ring and Nogo Retainer from the Shear Ring Collar.
Shear Ring Collar

item 3

item 20
Page: 73
5. Remove either two of Shear Ring (21,000 lbs) or Shear Ring (16,000 lbs) from the Shear Ring and Nogo Retainer.

item 21

item 20

item 21

item 21

item 20

item 21
Page: 74
6. Remove Shear Ring and Nogo Retainer from the Upper Crossover.

item 20
Upper Crossover
item 4
7. Remove two sets of O-Rings and Back-up Rings (O-Ring 129 and Solid Back-up Ring 129 form a set) from inside the Upper Crossover.
Upper Crossover
item 4

item 312
O-Ring 129
item 216

item 312
O-Ring 129
item 216
8. Remove O-Ring 131 and Solid Back-up Ring 131 from down hole end of the Upper Crossover.
Upper Crossover
item 4
O-Ring 131
item 217

item 313
Page: 75
Bullnose Nozzle
Bullnose Nozzle with Memory Gauge 1. Unthread Memory Gauge from Bullnose Nozzle.
Bullnose Nozzle
item 16
Memory Gauge
item 41
2. Unthread Rear Jetting Crossover from Bullnose Nozzle.

item 15
Bullnose Nozzle
item 16
3. Remove O-Ring 116 and Solid Back-up Ring 116 from Bullnose Nozzle.
Bullnose Nozzle
item 16
O-Ring 116
item 208

item 305
Page: 76
4. Unthread two of the Swirl Nozzle from the Bullnose Nozzle.
Swirl Nozzle
item 253
Bullnose Nozzle
item 16
Swirl Nozzle
item 253
5. Go to the next section but skip the first two steps. Bullnose Nozzle Without Memory Gauge 1. Unthread Rear Jetting Crossover from Bullnose Nozzle.

item 15
Bullnose Nozzle
item 16
2. Unthread two of the Swirl Nozzle from the Bullnose Nozzle.
Swirl Nozzle
item 253
Bullnose Nozzle
item 16
Swirl Nozzle
item 253
Page: 77
3. Unthread Rear Jetting Crossover. Note: If Shift Mechanism Option, then unthread the Rear Jetting Crossover from the J-Slot External Housing.

item 14

item 15
If using Sand-Vac Lockout or Well-Vac Lockout Option, then unthread the Rear Jetting Crossover from the Burst Disc Replacement Crossover.
Burst Disc Replacement Crossover

item 19

item 15
4. Unthread Half Dog Orifice from Rear Jetting Crossover.
Half Dog Orifice

item 36

item 15
5. Remove O-Ring 010 from Rear Jetting Crossover.
O-Ring 010
item 200

item 15
Page: 78
6. Unthread three of Pump Oil Plug from Rear Jetting Crossover. Note: Use 5/32" Allan wrench to loosen plugs.
Pump Oil Plug

item 256

item 15
Pump Oil Plug

item 256
Pump Oil Plug

item 256
7. Remove three O-Ring 902 from Pump Oil Plug.
Pump Oil Plug

item 256
O-Ring 902
item 257
Page: 79
8. Remove O-Ring 125 from Rear Jetting Crossover.

item 15
O-Ring 125
item 213
Options
Well-Vac Lockout Option
1. Remove Well-Vac Lockout from Burst Disk Replacement Crossover.

item 19
Well-Vac Lockout
item 34
Page: 80
2.
Remove O-Ring 122 and Solid Back-up Ring 122 from Well-Vac Lockout.
Well-Vac Lockout
item 35
O-Ring 122
item 211

item 308
Sand-Vac Lockout Option

1. Remove Sand-Vac Lockout from Burst Disk Replacement Crossover.

item 19
Sand-Vac Lockout
item 35
2.
Unthread the Half Dog Orifice from uphole end of Sand-Vac Lockout.
Half Dog Orifice

item 36
Sand-Vac Lockout
item 35
Page: 81
3.
Remove O-Ring 010 from uphole end of Sand-Vac Lockout.
O-Ring 010
item 200
Sand-Vac Lockout
item 35
4.
Remove O-Ring 122 and Solid Back-up Ring 122 from down hole end of Sand-Vac Lockout
Sand-Vac Lockout
item 35
O-Ring 122
item 211

item 308
Shift Mechanism Option

Note: 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 without appropriate supervision and/or training. 1. Unthread Burst Disk Replacement Crossover from J-Slot Housing Extension.

item 19

item 13
Page: 82
2. Unthread J-Slot Housing Extension from J-Slot External Housing.

item 13

item 14
3. Remove O-Ring 125 and Solid Back-up Ring 125 from J-Slot Housing Extension.

item 13

item 309
O-Ring 125
item 213
4. Remove assembled Shift Mechanism from J-Slot External Housing.

item 14
5. Remove O-Ring 125 and Solid Back-up Ring 125 from J-Slot External Housing.

item 14

item 309
O-Ring 125
item 213
Page: 83
6. Unthread Half Dog Orifice from the J-Slot Shaft.
Half Dog Orifice

item 36
J-Slot Shaft
item 37
7. Remove O-Ring 010 from the J-Slot Shaft.
O-Ring 010
item 200
J-Slot Shaft
item 37
8. Insert assembled Shift Mechanism into Spring Compressor Housing.

item T2
9. Orient the flat end of Spring Compressor End facing down hole, then insert into Spring Compressor Housing.

item T3

item T2
Page: 84
10. Place Spring Compressor Housing into a vise. Note: Tighten Spring Compressor End using a wrench.

item T3

item T2
11. Remove O-Ring 019 from J-Slot Valve Body.
J-Slot Valve Body

item 39
O-Ring 019
item 203
Page: 85
12. Remove two of J-Slot Pin from J-Slot Valve Body.
J-Slot Pin
item 350
J-Slot Valve Body

item 39
J-Slot Pin
item 350
13. Unthread Spring Compressor End from Spring Compressor Housing. Reverse orientation of Spring Compressor End and thread into Spring Compressor Housing. Note: Tighten using a wrench.

item T3

item T2
Page: 86
14. Unthread J-Slot End with a screwdriver.

item T2
J-Slot End
item 40
15. Unthread Spring Compressor End using a wrench.

item T3

item T2
Page: 87
16. Remove Spring Compressor End from Spring Compressor Housing.

item T3

item T2
17. Remove assembled Shift Mechanism from Spring Compressor Housing.
Assembled Shift Mechanism

item T2
18. Remove J-Slot End from the J-Slot Valve Body. Note: Loosen using a 5/8" Screwdriver.
J-Slot Valve Body

item 39
J-Slot End
item 40
19. Remove assembled J-Slot Valve Body from the J-Slot Shaft.
J-Slot Shaft
item 37
J-Slot Valve Body

item 39
Page: 88
20. Remove Thrust Bearing from the J-Slot Shaft.
J-Slot Shaft
item 37
Thrust Bearing
item 325
21. Remove Thrust Bearing Washer from the J-Slot Shaft.
J-Slot Shaft
item 37
Thrust Bearing Washer

item 376
22. Remove O-Ring 110 and Solid Back-up Ring 110 from the J-Slot Shaft.
J-Slot Shaft
item 37
O-Ring 110
item 204

item 302
23. Remove every Disc Spring from the J-Slot Shaft. Note: There should be 61 High Pressure Disc Spring or 65 Low Pressure Disc Spring.
Disc Spring
item 400
J-Slot Shaft
item 37
Page: 89
24. Remove J-Slot Bearing Washer from up hole end of J-Slot Valve Body.

item 38
J-Slot Valve Body

item 39
25. Remove Slydring from inside the J-Slot Bearing Washer.
Slydring
item 316

item 38
26. Remove O-Ring 119 and Solid Back-up Ring 119 from the J-Slot Valve Body.
J-Slot Valve Body

item 39
O-Ring 119
item 210

item 307
Page: 90
27. Remove the HP J-Slot Seal and O-Ring 132 from inside up hole end of J-Slot Valve Body.
HP J-Slot Seal
item 317
O-Ring 132
item 218
J-Slot Valve Body

item 39
28. Remove O-Ring 115 and Solid Back-up Ring 115 from inside up hole end of J-Slot Valve Body.
O-Ring 115
item 207

item 304
J-Slot Valve Body

item 39
Tool Disassembly
1. Unthread the Bullnose Crossover from the Burst Disk Replacement Crossover.
Bullnose Crossover
item 12

item 19
Page: 91
2. Use needle-nose pliers to pull out Spirlok, 1.188 from down hole end of the Burst Disk Replacement Crossover.
Spirlok, 1.188
item 377

item 19
Spirlok, 1.188
item 377
3. Slide Filter Spacer from Burst Disk Replacement Crossover.

item 19
Filter Spacer
item 42
4. Unthread Lee Filter from Filter Spacer.
Lee Filter
item 100
Filter Spacer
item 42
5. Use needle-nose pliers to pull out Spirlok, 1.188 from uphole end of the Burst Disk Replacement Crossover.
Spirlok, 1.188
item 377

item 19
Spirlok, 1.188
item 377
Page: 92
6. Remove two sets of O-Rings and Back-up Rings (O-Ring 125 and Solid Back-up Ring 125 form a set) from either end of the Burst Disk Replacement Crossover.
O-Ring 125
item 213

item 309

item 309
O-Ring 125
item 213

item 19
7. Unthread the Bullnose Crossover from the Sand Intake Crossover.

item 10
Bullnose Crossover
item 12
8. Remove O-Ring 129 and Solid Back-up Ring 129 from Sand Intake Crossover.

item 10

item 312
O-Ring 129
item 216
Page: 93
9. Remove Suction Screen from Sand Intake Crossover.

item 10
Suction Screen
item 11
10. Unthread Nozzle Retainer Locknut from Nozzle Retainer. Note: Loosen with adjustable wrenches as shown.
Nozzle Retainer
item 34

item 251
Page: 94
11. Unthread Nozzle Retainer Nut from Nozzle Retainer.
Nozzle Retainer
item 34
Nozzle Retainer Nut

item 250
12. Unthread Nozzle Retainer from Sand Intake Crossover.

item 10
Nozzle Retainer
item 34
Page: 95
Power Nozzle
1. Place Nozzle Retainer Cap into Power Nozzle Clamp.
Power Nozzle Clamp

item T1
Nozzle Retainer Cap

item 32
2. Place Power Nozzle Clamp into a vise. Loosen Nozzle Retainer Cap from Nozzle Retainer. Note: Remove Power Nozzle assembly from the vise and Power Nozzle Clamp to continue.
Power Nozzle Clamp

item T1
Nozzle Retainer
item 34
Nozzle Retainer Cap

item 32
Page: 96
3. Unthread the Nozzle Retainer Cap from the Nozzle Retainer.
Nozzle Retainer Cap

item 32
Nozzle Retainer
item 34
4. Remove the Power Nozzle from inside the Nozzle Retainer Cap.
Nozzle Retainer Cap

item 32
Power Nozzle
item 33
5. Remove O-Ring 013 and Solid Back-up Ring 013 from up hole end of Nozzle Retainer Cap.

item 300
O-Ring 013
item 201
Nozzle Retainer Cap

item 32
6. Unthread Fluid Exchanger from Sand Intake Crossover.
Fluid Exchanger
item 8

item 10
Page: 97
7. Remove O-Ring 118 and Solid Back-up Ring 118 from inside the down hole end of Sand Intake Crossover.

item 10

item 306
O-Ring 118
item 209
8. Remove O-Ring 212 and Solid Back-up Ring 212 from inside the up hole end of Sand Intake Crossover.
O-Ring 212
item 221

item 315

item 10
9. Unthread Throat Retainer Nut from the Fluid Exchanger.
Fluid Exchanger
item 8
Throat Retainer Nut

item 31
10. Remove Throat from Throat Retainer Nut.
Throat
item 30
Throat Retainer Nut

item 31
Page: 98
11. Slide Fluid Exchange Tube from the Fluid Exchanger.
Fluid Exchanger
item 8
Fluid Exchange Tube

item 9
12. Unthread Roll-on and Filter Housing from the Fluid Exchanger.

item 5
Fluid Exchanger
item 8
13. Remove the Diffuser from inside the Fluid Exchanger. Note: To remove the Diffuser, tap the end of the Fluid Exchanger on a soft surface and the Diffuser should fall out.
Fluid Exchanger
item 8
Diffuser
item 29
14. Remove O-Ring 207 from inside the Diffuser.
Diffuser
item 29
O-Ring 207
item 219
Page: 99
15. Remove O-Ring 210 and Solid Back-up Ring 210 from the Diffuser.
Diffuser
item 29
O-Ring 210
item 220

item 314
16. Remove O-Ring 131 and Solid Back-up Ring 131 from the up hole end of the Fluid Exchanger. Remove three sets of O-Rings and Back-up Rings (O-Ring 129 and Solid Back-up Ring 129 form a set) from the Fluid Exchanger.
Fluid Exchanger
item 8
O-Ring 131
item 217
O-Ring 129
item 216
O-Ring 129
item 216
O-Ring 129
item 216

item 313

item 312

item 312

item 312
17. Unthread Pin To Pin Crossover from the Roll-on and Filter Housing.

item 6

item 5
Page: 100
18. Remove two of O-Ring 132 from inside the Roll-on and Filter Housing.
O-Ring 132
item 218

item 5
O-Ring 132
item 218
19. Slide off Pin To Pin Crossover from Filter Upper Spacer.

item 6
Filter Upper Spacer

item 25
20. Remove two sets of O-Rings and Back-up Rings (O-Ring 131 and Solid Back-up Ring 131 form a set) from Pin To Pin Crossover.

item 6
O-Ring 131
item 217

item 313

item 313
O-Ring 131
item 217
21. Pull off Filter Upper Spacer from up hole end of Filter Tube.
Filter Upper Spacer

item 25
Filter Tube
item 26
Page: 101
22. Slide off Filter Tube from Filter Lower NPT Spacer.
Filter Tube
item 26

item 28
23. Remove two of O-Ring 113 and two of O-Ring 123 from Filter Upper Spacer.
Filter Upper Spacer

item 25
O-Ring 113
item 205
O-Ring 123
item 212
O-Ring 113
item 205
O-Ring 123
item 212
24. Remove two of O-Ring 123 and two of O-Ring 113 from Filter Lower NPT Spacer.

item 28
O-Ring 123
item 212
O-Ring 113
item 205
O-Ring 123
item 212
O-Ring 113
item 205
25. Unthread Filter Lower NPT Spacer from Power Fluid Filter.
Power Fluid Filter

item 27

item 28
Page: 102
Troubleshooting
OBSERVATION During Surface test, the tool will not shift modes POSSIBLE CAUSE -J-slot pins are not sliding or are incorrectly installed -insufficient injection pressure to overcome shift mechanism springs -J-slot seals are leaking RECOMMENDED ACTION -remove and replace j-slot pins -perform function test in the shop on the shifting mechanism to ensure that the j-slot shifts smoothly -increase injection pressure -redress the Shift Mechanism
During surface test, tool jets slightly from nozzles in WellVac mode (mode verified) Injection flow rate higher than predicted by Circa
-incorrect mode -Surface lines leaking -outer housing seal failure -cct connector seal failure -injection flow path leakage -nozzle tip eroded, broken or incorrect -inline filter is restricted -incorrect nozzle in tool -insufficient friction reducer -suction screen is restricted -throat is worn out -low injection rate -tool has incorrect nozzle/throat setup -insufficient friction reducer insufficient wellbore fluid level (vertical well) -Tool pressure is too high -Sand loading is too high -suction rate too low -penetration rate too low -tool not in sand fill insufficient fluidization (horizontal well) -penetration rate too high -insufficient fluidization (vertical well)
-verify mode of tool (above fill) -Inspect surface lines for leakage -POOH and perform surface test to locate failure -replace failed component -inspect nozzle for damage and appropriate sizing -POOH and replace/clear filter -POOH and install correct nozzle -maintain maximum friction reduction -backflush screen -POOH and replace throat -ensure job has been correctly modelled in Circa by trained personnel -increase injection rate -maintain maximum friction reduction -backfill wellbore from surface -reduce tool pressure -reduce trip speed -increase forward nozzle rate - increase injection pressure/rate -increase penetration rate -increase forward nozzle jetting rate -confirm tool depth and fill depth -decrease penetration rate -increase forward nozzle jetting rate
Injection flow rate lower than predicted by Circa
Low returns or no returns
Throat has high wear rate
Power Nozzle has high wear rate Low sand concentration in returns (tool operating according to model) High sand concentration in returns (tool operating according to model)
Page: 103
Page: 104
Appendix
Page: 105
Page: 106
Part Kits for Well-Vac v.2 (2-1/8)

Main Kit (SAP No. 664706)
QTY 2 1 1 1 1 1 SAP NO. 11241 664707 664708 664709 664710 10024 DESCRIPTION Tool, WellVac / MiniVac, 2-1/8 Spare Parts Kit Fixtures Kit O-Ring & Viton Backup Kit Hand Tools Kit Case, Stronguard Series
Spare Parts Kit (SAP No. 664707)

QTY 1 1 10 10 10 10 1 2 2 1 4 2 1 1 1 1 1 4 1 1 1 10 1 1 SAP NO. 10287 10782 10276 10772 10277 10773 10827 10274 10770 10774 10775 11120 10271 10767 10771 10275 10840 10841 10780 10286 10845 10273 10843 10844 DESCRIPTION Nogo Ring Shear Ring Collar Shear Ring (21,000 lbs) Aluminum Shear Ring (16,000 lbs) Aluminum Shear Ring (21,000 lbs) Brass Shear Ring (16,000 lbs) Brass Sand Intake Crossover Suction Screen, Horizontal Suction Screen, Vertical Power Fluid Filter, .015 Diffuser Diffuser, Short Sandvac Lockout (1.75) Wellvac Lockout (1.75) Bullnose Nozzle Bullnose Nozzle for Memory Gauge Throat Retainer Nut Nozzle Retainer Cap Nozzle Retainer Nut Nozzle Retainer Locknut J-Slot Valve Body (1.75) HP J-Slot Seal (1.75) HP J-Slot Shaft J-Slot Bearing Washer
Well-Vac v.2 Service Manual (2-1/8)
Page i
122 130 5 5 10 2 10 10 10 10 5 5 10 12 10 1 10
10862 9217 10017 10018 9212 11242 11121 9224 10769 10768 600145 8999 664725 10423 10860 11055 22651
Disc Springs, High Pressure Disc Springs, Low Pressure Thrust Bearing Thrust Bearing Washer J-Slot Pin J-Slot End Swirl Nozzle, 0.045 Swirl Nozzle, 0.060 Half Dog Orifice .035 Half Dog Orifice .045 Half Dog Orifice .063 Half Dog Orifice .070 Half Dog Orifice .055 Pump Oil Plug Spirlok 1.188 Spare Parts Box Spare Parts Container
Fixtures Kit (SAP No. 664708 )

QTY 1 1 1 1 1 set 1 1 1 1 1 1 1 1 1 SAP NO. 10861 601923 9776 601917 664712 664713 664714 27249 664715 664716 664717 664718 664719 23893 DESCRIPTION Snake Tube Snake Crossover Snake Grapple Rope Socket Snake Assembly Nut Power Nozzle Clamp Spring Compressor Housing Spring Compressor End Blank Power Nozzle Kit Test Fixture Test Cap (Box, Ported, 1.84-10SA) Test Cap (Box, Blank, 1.84-10SA) Test Cap (Pin, 1.47-10SA) Test Cap (Box, Ported, 1.47-10SA) Go/No Go Gauge Set
Blank Power Nozzle Kit (SAP No. 27249)

QTY 1 1 SAP NO. 10501 10502 DESCRIPTION Blank Power Nozzle #3 & #4 Blank Power Nozzle #5
Page ii
1 1
22391 10453
Blank Power Nozzle #6 Blank Power Nozzle #7 & #8
O-Ring and Viton Backup Kit (SAP No. 664709)

QTY 25 25 25 25 25 50 75 25 25 25 25 25 50 50 25 100 50 25 25 25 25 50 50 25 25 25 75 25 25 25 25 25 50 25 100 50 25 SAP NO. 12354 12357 12358 12363 12403 12406 12407 12408 12409 12411 12412 12415 12416 12418 12421 12422 12424 12425 12478 12481 12483 602079 25197 10849 10850 10851 9611 10852 10853 9612 10854 22359 10855 9269 9613 10857 10858 DESCRIPTION O-Ring 010 Viton 90D O-Ring 013 Viton 90D O-Ring 014 Viton 90D O-Ring 019 Viton 90D O-Ring 110 Viton 90D O-Ring 113 Viton 90D O-Ring 114 Viton 90D O-Ring 115 Viton 90D O-Ring 116 Viton 90D O-Ring 118 Viton 90D O-Ring 119 Viton 90D O-Ring 122 Viton 90D O-Ring 123 Viton 90D O-Ring 125 Viton 90D O-Ring 128 Viton 90D O-Ring 129 Viton 90D O-Ring 131 Viton 90D O-Ring 132 Viton 90D O-Ring 207 Viton 90D O-Ring 210 Viton 90D O-Ring 212 Viton 90D O-Ring 902 Viton 90D O-Ring 903 Viton 90D Solid Backup Ring 013, Viton 90 Solid Backup Ring 014, Viton 90 Solid Backup Ring 110, Viton 90 Solid Backup Ring 114, Viton 90 Solid Backup Ring 115, Viton 90 Solid Backup Ring 116, Viton 90 Solid Backup Ring 118, Viton 90 Solid Backup Ring 119, Viton 90 Solid Backup Ring 122, Viton 90 Solid Backup Ring 125, Viton 90 Solid Backup Ring 128, Viton 90 Solid Backup Ring 129, Viton 90 Solid Backup Ring 131, Viton 90 Solid Backup Ring 210, Viton 90
Page iii
25 25 1
10859 664711 11055
Solid Backup Ring 212, Viton 90 Slydring, 0.160 x .063 Spare Parts Box
Hand Tools Kit (SAP No. 664710)

QTY 2 2 1 1 1 1 1 1 1 1 1 1 1 1 3 1 1 1 1 1 SAP NO. 9656 22551 27301 27295 22879 27261 9625 12026 27311 22653 11376 9735 27285 27297 27367 27315 27359 27279 9556 22305 DESCRIPTION Gear Wrench, 1.75 Gear Wrench, 2.125 Pick set, set of 4 Crescent Wrench, 12 Crescent Wrench, 18 Screwdriver, flat tip, Screwdriver, flat tip, 5/16 Allen Key Set, Imperial Pipewrench, 12 Aluminum Roll-on tool, with cutter and roller Spare cutter Spare roller Hammer, ball peen Pick, long Flux brush Neo, CV500, 1 lb. Motor assy lube, Lubriplate, 10oz Punch, 5/32 Teflon Thread Sealant Copper Cote
Go/No Go Gauge Set Kit (SAP No. 23893)

QTY 1 1 1 1 1 1 1 1 1 1 SAP NO. 10456 10459 10460 10463 10464 10465 10490 10491 23753 23755 DESCRIPTION Gauge, Go NoGo .077-.081 (Half Dog .075) Gauge, Go NoGo .081-.086 (Half Dog .08) Gauge, Go NoGo .069-.074 (Powernozzle#3) Gauge, Go NoGo .079-.084 (Powernozzle#4) Go-NoGo .089-.094 (Nozzle#5/Throat#1) Go-NoGo .101-.106 (Nozzle#6/Throat#2) Gauge, Go NoGo .145-.152 (Throat#5) Gauge, Go NoGo .163-.168 (Throat#6) Gauge, Go NoGo .061-.066 (Swirl Nozzle) Gauge, Go NoGo .071-.074 (Half Dog .070)
Page iv
1 1 1 1 1
23757 23759 23243 27245 27247
Go-NoGo .112-.119 (Nozzle #7/Throat#3) Go-NoGo .128-.133 (Nozzle#8/Throat#4) Gauge, Go NoGo .183-.188 (Throat#7) Well-Vac Gauge, Go NoGo .207-.212 (Thraot#8) Well-Vac Gauge, Go NoGo .235-.240 (Throat#9) Well-Vac
Page v
1.5 - .75 Concentric Tubing Surface Connector
200
201
250
1.5 - 1 Concentric Tubing Surface Connector
200
201
250
2 - 1 Concentric Tubing Surface Connector
200
201
250
Tubing Surface Connector Fitting Weld
ADD/CHANGE NOTES
Table of Item Numbers

(For cross referencing between General Assembly Drawing, Parts List and Manual.) item 1, page, 57, 63, 67, 72 item 2, page, 67, 73 item 3, page, 67, 73 item 4, page, 64, 65, 69, 71, 75 item 5, page, 29, 30, 68, 69, 71, 99, 100, 101 item 6, page, 28, 29, 71, 100, 101 item 8, page, 30, 31, 32, 33, 97, 98, 99, 100 item 9, page, 30, 99 item 10, page, 32, 33, 35, 36, 37, 93, 94, 95, 97, 98 item 11, page, 36, 94 item 12, page, 37, 39, 91, 93 item 13, page, 51, 82, 83 item 14, page, 49, 50, 51, 54, 78, 83 item 15, page, 52, 53, 54, 55, 56, 76, 77, 78, 79, 80 item 16, page, 54, 55, 56, 76, 77 item 19, page, 38, 39, 40, 41, 51, 54, 78, 80, 81, 82, 91, 92 item 20, page, 65, 67, 72, 73, 75 item 21, page, 66, 74 item 22, page, 68, 72 item 23, page, 60, 63, 68, 72 item 24, page, 68, 69, 71, 72 item 25, page, 27, 28, 29, 101, 102 item 26, page, 28, 101, 102 item 27, page, 27, 102 item 28, page, 27, 28, 102 item 29, page, 31, 99, 100 item 30, page, 32, 98 item 31, page, 32, 98 item 32, page, 33, 34, 96, 97 item 33, page, 33, 97 item 34, page, 33, 34, 35, 80, 94, 95, 96, 97
Page: i
item 35, page, 39, 40, 41, 81, 82 item 36, page, 40, 48, 53, 78, 81, 84 item 37, page, 43, 44, 48, 84, 88, 89 item 38, page, 42, 90 item 39, page, 41, 42, 44, 47, 48, 85, 86, 88, 90, 91 item 40, page, 44, 46, 47, 87, 88 item 41, page, 56, 76 item 42, page, 38, 92 item 100, page, 38, 92 item 200, page, 39, 48, 53, 78, 82, 84 item 201, page, 33, 97 item 203, page, 48, 85 item 204, page, 43, 89 item 205, page, 27, 72, 102 item 206, page, 60 item 207, page, 41, 91 item 208, page, 55, 76 item 209, page, 32, 98 item 211, page, 82 item 212, page, 27, 102 item 213, page, 37, 93 item 215, page, 62 item 216, page, 30, 57, 65, 75, 100 item 217, page, 30, 100 item 218, page, 29, 41, 68, 71, 91, 101 item 219, page, 31, 99 item 221, page, 32, 98 item 250, page, 35, 36, 95 item 251, page, 35, 36, 94 item 253, page, 54, 55, 77 item 254, page, 64 item 256, page, 52, 53, 79 item 257, page, 52, 79 item 300, page, 33, 97 item 302, page, 43, 89
Page: ii Well-Vac v.2 Service Manual (2-1/8")
item 303, page, 60 item 304, page, 41, 91 item 305, page, 55, 76 item 306, page, 32, 98 item 309, page, 37, 93 item 312, page, 57, 65, 75 item 313, page, 30 item 315, page, 32, 98 item 316, page, 42, 90 item 317, page, 41, 91 item 325, page, 44, 89 item 350, page, 47, 86 item 376, page, 43, 89 item 377, page, 38, 92 item 400, page, 43, 89 item 500, page, 62, 63 item 501, page, 63 item 502, page, 63, 64 item 503, page, 63 item T1, page, 34, 96 item T2, page, 44, 45, 46, 47, 84, 85, 86, 87, 88 item T3, page, 45, 46, 84, 85, 86, 87, 88
Page: iii

Well-Vac v.2 2-18

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Well-Vac v.

February 15, 2007

Read Manual Before Servicing Tool

Symbols Used in Service Manuals

Service Manual Conventions

Upper Filter Spacer

Essential Disassembly Requirements

Essential Assembly Requirements

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Specifications .................................................................................. 5 How it works .................................................................................... 7 Operational Mode ............................................................................ 9

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

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

Troubleshooting .......................................................................... 103 Appendix...................................................................................... 105 Parts Kit Drawings

Table of Item Numbers

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

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

Natural Sorting / Bridging Influx / Sloughing

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

Figure 2 Surface Equipment Schematic

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

Crane Truck Wellhead, Injector & Support Structure

Flow Meter Pressure Transducer High Pressure Filter

Dual Compartment Rig Tank

Sand-Vac Pumper with Filter System CCT Reel Unit

400 bbl Tanks

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

Minimum operating temperature

Maximum operating temperature depends on aluminum shear rings... depends on O-Ring...

Shipping weight including cases and hand tools

75 lbs 10,000 psi 6,800 psi 21,000 lbs

34 kg 68.9 MPa 46.9 MPa 9,341 daN

Minimum wellbore diameter

Concentric Coiled Tubing sizes available O-Rings

Viton 75 duro Grease/lubricants - CV 500 Joint Grease - White Lubriplate

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

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

Intake Ports (fluid and wellbore material)

Figure 5 - CCT / Well-Vac

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

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

How Mode Switching Occurs

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

MODE: External jets: J-slot shaft:

WELL-VAC off short stroke

SAND-VAC On long stroke

Determining Mode Setting

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

Sand Cleanout in Vertical Wells

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

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

BHA / Cleanout Operation

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

Sand Removal Mode (Sand-Vac mode)

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

Fluid Removal Mode (Well-Vac mode)

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

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

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

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