Issue A Prepared by: DLS Number:

Technical Manual
Date 25/08/09 Approved by: MRM 0000006931

High Expansion Shifting Tool

Size: 2.2”

Description
The Caledyne High Expansion Shifting Tool (HEST) is an
ultra slim shifting tool, which may be used to operate down
hole tools having a significantly larger ID than the restriction
above. The HEST is run and operated on coil tubing.

Various key sets may be used to configure the tool to

operate in profiles from 3-1/2” to 4-1/2” tubing.

Key Benefits
Ultra slim for installation through 2-7/8” bypass tubing.

Keys expand out to all 3-1/2” to 4-1/2” nominal profiles.

Bi-directional key sets. No need to modify the tool for

open/close operations.

Field replaceable choke nozzle to vary pump pressure

required to activate keys.

Emergency shear facility to collapse keys if the keys do not

retract.

Applications
Coil Tubing deployed shifting tool

Certification
In house qualification programme. Any particular customer
requirements may be accommodated in the development
process. We welcome customer involvement in the
qualification programme.

Contact Caledyne for details.

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© 2009 T18 issue 1
Issue A Prepared by: DLS Number:
Technical Manual
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Technical Specification
Parameter Value
To set in casing size 3-1/2” – 4-1/2”
ODmax 2.200” (55.88mm)
IDmin N/A
Length 53” (1.34m)
Top connection 1.500” AMMT
Bottom connection Bullnose
Metallurgy AISI4140-45 18-22Rc 80ksi per NACE MR0175
Elastomer VITON 70HD
Temperature range 32-250°F (0-121°C)

Bill of Material
Item Description Qty Part number
1 Top Sub 1 0000006042
2 Piston Chamber 2 0000004150
3 Piston 2 0000004154
4 Shear Mandrel 2 0000004155
5 Shear Sub 2 0000004156
6 Main Housing 1 0000004149
7 Return Spring 6 0000004184
8 Flowtube 1 0000004148
9 4.9mm Orifice 1 0000006901
10 Bottom Sub 1 0000004153
11 ¼” UNC Set Screw x 3/16” Long 4 0000005225
12 ¼” UNC x ¼” Long Brass Shear Screw 24 0000001371
13 Size 108 V70 O-ring 2 0000004177
14 Size 113 V75 O-ring 1 0000005349
15 Size 222 V70 O-ring 4 0000002929
16 Key Set 1 SEE TABLE BELOW

N/A Redress Kit F/2.200” HEST 1 0000004192

Sundry Equipment
N/A 1 ½” AMMT Test Cap 1 0000006241
N/A ¼” NPT X ¼ Compression 1 0000006244
N/A Test Plug 1 0000005971
N/A O-Ring #113 1 0000005349
N/A Orifice W/ TBA dia hole 1 TBA
N/A Orifice W/ TBA dia hole 1 TBA

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Technical Manual
Date 25/08/09 Approved by: MRM 0000006931

Assembly

2.200” HEST Key Sets

Tubing Size Seal Bore Size Key Set Assy No. Upper Key Part No. Lower Key Part No. Gauge Ring Part No.
2-7/8” 2.312” 0000010866 0000010863 0000010864 0000010865
3-1/2” 2.562” 0000006933 0000005953 0000006904 0000006496
3-1/2” 2.562” M 0000006934 0000006226 0000006912 0000006496
3-1/2” 2.750” 0000006938 0000006937 0000006936 0000006944
3-1/2” 2.812” 0000006945 0000006939 0000003940 0000003944
4” 3.125” 0000006953 0000006950 0000006951 0000006952
4” 3.312” 0000006957 0000006954 0000006955 0000006956
4-1/2” 3.437” 0000006961 0000006958 0000006959 0000006960
4-1/2” 3.500” 0000006965 0000006962 0000006963 0000006964
4-1/2” 3.563” 0000006969 0000006966 0000006967 0000006968
4-1/2” 3.688” 0000006973 0000006970 0000006971 0000006972
4-1/2” 3.812” 0000006977 0000006974 0000006975 0000006976

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© 2009 T18 issue 1
 Issue A Prepared by: DLS Number:
Technical Manual
Date 25/08/09 Approved by: MRM 0000006931

Assembly & Factory Acceptance Test Procedure

Prior to assembly, all parts should be checked for burrs, swarf or any signs of excessive wear or damage. Pay
particular attention to threads and seal surfaces. A suitable grease such as Shell Albida should be used to aid
assembly.

1. Assembly

a. Grip Main Housing (item 6) in a suitable vice at either end leaving the slots clear.

b. Assemble the Upper and Lower Keys into sets by inserting 2 of the Return Springs (item 7)
through the end windows on each key to locate in the Key slots.

c. Feed upper end of Upper Key through slot and feed up into Main Housing bore far enough to
allow lower end of Lower Key to be inserted into lower Main Housing bore. Centralise Keys in
slot. Repeat until all Key sets are in position.

d. Feed Flowtube (item 8) through Main Housing and Upper and Lower Keys until it is
approximately centralised.

e. Assemble two sets of shear subassemblies by assembling Shear Mandrels (item 4) to Shear
Subs (item 5) with Shear Screws (item12). The load to shear off in case of emergency is set
at this point. Shear screws can be left out to define shear load. NB. Only one shear
subassembly will shear.

Load to Shear

16000

14000

12000
Total Shear Load (lbf)

10000

8000

6000

4000

2000

0
1 2 3 4 5 6 7 8 9 10 11 12
No. of Shear Screw s (Brass)

f. Insert the shear subassemblies over the ends of the Flowtube and into the upper and lower
ends of the Main Housing to butt against the ends of the Keys.

g. Make up Piston Chambers (item 2) to upper and lower end of Main Housing and retain with
Set Screws (item 11).
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h. Assemble O-rings (items 13 & 15) to Pistons (item 3) and fit Pistons over ends of Flowtube
and into Piston Chambers.

i. Fit O-ring (item 15) to Top Sub (item 1) and make up to upper end of Main Housing and
retain with Set Screw (item 11).

j. Fit O-ring (item 14) to Orifice (item 9) and insert into Bottom Sub (item 10).

k. Fit O-ring (item 15) to Bottom Sub and make up to lower end of Main Housing and retain with
Set Screw (item 11).

Witness point

Signature Date

Factory Acceptance Testing

a. Assemble as per assembly instructions above, replacing the Orifice (item 9) with the Test
Plug.

b. Make up the 1.500” AMMT Test Cap and connect to the test pump.

c. Slide the appropriate Gauge Ring for the required Key Set over the body of the tool.

d. Apply pressure and monitor to ensure HEST Keys inflate correctly and lock into the Gauge
Ring.

e. Bleed off pressure and disconnect from pump and remove test cap.

Reassemble with the correct Orifice.

Witness point

Signature Date

Disassembly

a. Disassembly is the reversal of the assembly procedure.

b. When disassembling the tool, set screws must be removed before attempting the break a
connection.

c. The seals and shear stubs should be disposed of. Visually inspect all parts for any signs of
damage, deformation or wear. Replace any damaged or worn parts and all seals.

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4. Shipping/Storage Preparations

• Fit thread protector to the upper connection.

• Place in a suitable shipping crate. Ensure that Silica Gel is included in the crate.

Care and Maintenance

1. The tool should be stored in a dry warehouse environment and protected from possible damage and
corrosion until it is required for use. The tool should be inspected before dispatch to rig-site and before
deployment.
2. After the tool has been used, it should be stripped, cleaned and inspected then rebuilt using the
appropriate redress kit (0000004192).
3. O-rings should be replaced every 9 months regardless of use.

Operational Procedures
These procedures are for guidance only and all operational requirements for a particular application
should be considered in advance and incorporated into a suitable programme of operations.

1. Assemble HEST to appropriate coiled tubing BHA.

2. Prior to running in hole circulate through coil to confirm operation of HEST and establish circulation
pump flow-rate and pressure required to inflate the Keys fully (the orifice size may be changed and
retested if required).
3. RIH as per standard coiled tubing procedure.
4. When approaching target depth, slow down running speed and begin pumping to inflate HEST.
5. Pick up and set down to establish drag weights.
6. Run to target depth and monitor for increase in loading when profile is located.
7. Shift profile sleeve up or down as required.
8. Reduce circulating rate to deflate HEST.
9. Re-inflate HEST and run through profile in required shift direction to confirm shift if desired.
10. Deflate HEST and POOH.

Contingency Measures

HEST does not auto-release

1. In the event that the tool does not auto-release, the tool may be sheared out by pulling/pushing to
shear the shear screws and then pulled to surface (see assembly instructions for shear load).

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Date 25/08/09 Approved by: MRM 0000006931

APPROXIMATE PUMP RATE CHART BY ORIFICE SIZE

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Operational Calculations
The chart on the previous page depicts typical working flow rate values for a 2.2” HEST. The chart is
read by finding the point where the operating (black) line intersects with the orifice size being used and
reading across to see the estimated flow rate required to run the HEST. These charts change with
different key sizes, fluid viscosity, temperature, etc so should only be used as a rough guide.

This is an approximate guideline only, prior to every job, it is recommended to follow the
procedures below.

1. With the gauge ring (item 18) around the HEST, start and increase the pump rate until the
keys are fully inflated and the gauge ring is secure but still free to move, record this pump rate
in the box provided.

2. Continue increasing the pump rate until the keys over expand and lock the gauge ring solid,
record this pump rate in the box provided.

Inflation pump rate Maximum pump rate

BBL/min BBL/min

3. To work out the optimal running pump rate use the equation.

Running pump rate = inflation pump rate + [(maximum pump rate - inflation pump rate)/4].

Enter the running pump rate in the box below

Running pump rate

BBL/min

For example:

4mm Orifice

Inflation pump rate Maximum pump rate

.07 BBL/min 0.32 BBL/min

Recommended running pump rate = inflation pump rate + [(maximum pump rate - inflation pump
rate)/4].

= 0.07+(0.32-0.7)/4 = 0.13 BBL/min

Running pump rate

0.13 BBL/min

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© 2009 T18 issue 1