2026 9.6 TST-3 Rev H

BJ SERVICES COMPANY, USA Service Tools Technical Manual Subject:

9.6 TST-3 Service Packer

Index No:

2026

Approval:

Revision: Doug Lehr

H

Date: August 29, 2006 Approval Date:

Page 1 of 26

August 31, 2006

TST-3 SERVICE PACKER - 9.63” 29.3-53.5 PPF DESCRIPTION The 9.63 TST-3 retrievable service packer is a high-pressure tool designed for use in sweet service wells at moderate temperature. It is used for service operations such as squeeze squeeze cementing, formation fracturing fracturing and tubular testing. The TST-3 features an integral bypass seal, which allows rapid running without additional tools under normal conditions. A system of hydraulic hydraulic hold-down buttons allows allows the TST-3 to to automatically grip the the casing when tubing pressure exceeds casing pressure, preventing preventing tool movement while while treating below the tool. These buttons retract when the tubing and casing pressures equalize equalize allowing easy retrieval. The TST-3 is a compression set packer designed to operate at differential pressures pressures up to 8,000 PSI above or below the packer. Operation is limited limited to 275°F with the standard elements and seals. It is possible to treat in temperatures up to 350°F for short periods of time using an optional higher temperature packing element system.

FEATURES AND BENEFITS Integral Unloader and Fluid Bypass. The TST-3 is well suited to operations such as spotting fluids while the tool is still set. The bypass design also allows allows circulation around around the bottom of the tool, allowing allowing rapid removal of debris, cement or treating fluids from the bottom of the tool.



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Revision: H

Date: August 29, 2006

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COMPANION EQUIPMENT Companion Tool

Technical Unit Number

BJ Hurricane Valve

2103

BJ Rotational Equalizing Valve

2105

BJ Unloader Valve

2007

SPECIFICATION GUIDE TST-3 Specification Guide (all dimensions in inches) Absolute Slip Range

Absolute Button Range

Casing Size

Casing Weight

Casing ID Range

Gauge Ring OD

Packing Element OD

Min

Max

Min

Max

9.6

47-53.5

8.535 - 8.681

8.218

7.937

8.220

8.760

8.130

9.073

Spacer Ring OD

8.168

Mandrel ID

3.00

Standard Connections

3-1/2 EU or



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PRESSURE, TEMPERATURE, AND MECHANICAL RATINGS The standard TST-3 packer is shipped with a 90 Durometer Nitrile bypass seal and a 90-70-90 Durometer Nitrile packing element system. All O-rings are Nitrile as well. This allows the packer to function appropriately in well temperatures up to 275°F and at differential pressures up to 8,000 PSI (tubing or annulus pressure). Consult Service Tools Engineering for optional 90 Durometer Bonded bypass seal and optional 90-80-90 durometer packing element systems availability. Packer Mechanical Limits All values listed are with a safety factor of 1.0. If these values are exceeded, the packer must be disassembled and thoroughly inspected for damage prior to returning the tool to service. It is recommended that if tensional loads are exceeded on the mandrel, that the mandrel, top and bottom subs be replaced regardless of whether any damage is apparent. 9-5/8” TST-3 Packer Family (all packers with 8015 8-X for assembly numbers)

Mandrel – Maximum Tensile load

388,400 lb.

Mandrel and Top and Bottom Subs – Maximum Torque

28,630 ft-lb.

Mandrel – Minimum Burst and Collapse (in cases where the tubing is plugged)

17,500 PSI

Burst and Collapse – minimum for all pressure containing parts

8,000 PSI

Minimum tailpipe weight when used as a storm packer

62,500 LBS.

OPERATING INSTRUCTIONS



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To Spot Fluids After the tool has been tested, release any pressure on the tubing and then the annulus. Pick the tool up to open the bypass, and unset the packer (if necessary). Begin spotting fluid. When the fluids are properly positioned, slack off to set the packer and close the bypass. Apply proper weight to the tool. Monitor the annulus and tubing pressures throughout the job.

To Release After pressure is released from the tubing and annulus, if possible, the annulus should be pressured to a minimum of two hundred PSI and held for at least 1 minute. This will help the hydraulic hold-down buttons retract. If pressuring the back-side is not possible, it may be necessary to work the tool up and down slowly to help the buttons retract. Releasing the tool and pulling from the hole too quickly (before the buttons can completely retract) can seriously damage the tool and may damage casing.

Reversing Out When squeezing and after setting sand plugs, when possible, reverse out. This helps to flush debris from the tool and works to insure that the tool is free after job completion.

To Reset The TST-3 can be set and released multiple times in the same trip to test casing or spot fluids at different locations . If the tool has an “Automatic-J”, picking the tool up a few feet will put it in the running position. If a manual J or manual L patterned control housing is being used, the tool may be pulled up the hole and reset simply by slacking



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Revision: H


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TROUBLESHOOTING Symptom

Packer will not start in hole

Possible Cause(s)

1) Drag blocks or gauge rings too large for casing

Possible Solution(s)

1a) Check gauge ring OD 1b) Check drag blocks 1c) Verify tool appropriateness for casing

Packer hangs up going in hole

Packer will not set

2) Insufficient pipe weight

2) Add drill collars or pipe weight as necessary

1) Packer trying to set

1) Pick tool up a couple of feet and rotate back to running position

2) Trash in hole

2) POOH make bit / scraper run and circulate 2 casing volumes to clean pipe

1) Drag blocks not gripping

1a) Move up or down 1 joint to see if packer will set 1b) Replace drag blocks and springs as necessary

2) Slips not gripping

2a) POOH replace slips as necessary 2b) POOH inspect tool for debris

3)

tool size

3) Verify tool appropriateness for



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ASSEMBLY LUBRICANTS The lubricants listed below will provide adequate protection and lubrication for the TST-3 packers in land and marine environments. Grease

Manufacturer

Liquid O-ring Polymer 400

Oil Center Research

ALCO EP

Jet-Lube

CC Lube KOPR-KOTE

Jet-Lube Jet-Lube



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Revision: H


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CALCULATING HYDRAULIC FORCES ON THE TOOL Effect of Tubing and Annulus Pressure on Unloader of TST-3 The Unloader Valve on the TST-3 is not hydraulically balanced for any particular tubing size. Therefore, changes in tubing pressure and annulus pressure will exert a force tending to open the unloader (by acting against tubing setdown weight) or exert a force tending to hold the unloader closed. The following material may be used to determine the magnitude of these forces for a given change in tubing or annulus pressure and also tell whether they are tending to open or close the unloader. The values given in the chart “Areas (in sq. ins.) Acted upon By Tubing and Annulus Pressures” are printed as positive or negative. These values are not only the number of square inches acted upon by the pressure change, but also the direction of the resultant force. The figures shown as positive will cause, with a pressure increase, a force tending to hold the unloader closed. The areas shown negative will result in an upward force, or a force tending to open the unloader. The directions of the



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Revision: H


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TST-3 Packer and Hydraulic Data Basic Packer Size

Tubing Data Drill Pipe Size

9-5/8” – TST-3

Weight Lbs./ft.

ID In.

Bypass Seal

Net Balance Piston Area

OD Area (in2)

ID Area (in2)

ID Area (in.)

OD Area (in2)

(in2)

To

Ti

Si

So

Bn

14.22

16.76

14.50

6 5/8

25.20

5.965

34.471

27.945

5 7/8

23.40

5.153

27.11

20.855

5½

24.70

4.670

23.758

17.128

5½

21.90

4.778

23.758

17.930

5

25.60

4.000

19.635

12.560

5

19.50

4.276

19.635

14.360

5

16.25

4.408

19.635

15.261

4½

22.82

3.500

15.900

9.621

4½

20.00

3.640

15.900

10.406

4½

16.60

3.826

15.900

11.497

4½

13.75

3.958

15.900

12.304



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Revision: H


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Where, Column 1 = -(So-Ti) + (Bn) Column 2 = (So-To) – (Bn) Column 3 = -Ti Column 4 = -(Si-Ti) Column 5 = Si-To Column 6 = Si-Ti Column 7 = Si-To

To = Tubing O.D. Area Ti = Tubing I.D. Area So = Bypass Seal O.D. Area Si = Bypass Seal I.D. Area Bn = Net Balance Piston Area

WHEN TUBING PRESSURE IS GREATER THAN ANNULUS PRESSURE AT THE TOOL: Caution: Tubing movement calculation may be necessary to fully understand the forces on the packer and should be run prior to the job.

1.

Multiply the change in the tubing pressure at the tool by Column 1. L1 = ΔP x Tubing Area Col. 1

2.

Multiply the change in annulus pressure at the tool by Column 2. L2 = ΔP1 x Annulus Area Col. 2 If the total of these forces is tending to open the unloader (negative), and is greater than the original pack-off



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1.

Revision: H


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Multiply the change in the tubing pressure at the tool by Column 1. L1 = ΔP x Tubing Area Col. 1 = 3000 psi x 12.10 sq. in. = 36,300 lb.

2.

Multiply the change in annulus pressure at the tool by Column 2. L2 = ΔP1 x Annulus Area Col. 2 = 0 psi x (-17.38) sq. in. = 0 lb. L1 + L2 = 36,300 + 0 = 36,300 lb.>0 lb. (tends to keep unloader valve closed)

3.

Multiply the tubing pressure by Column 3. (Tubing not secured at surface) L3 = ΔP x Tubing ID Area Col. 3 = 3000 psi x (-14.36) = -43,080 lb.

4.

Adding the forces, L1 + L2 + L3 = (36,300 + 0 + -43,080) lb. = -6,780 lb., will tend to open the unloader seal. Therefore, an additional 6780 lbs is needed for a total of 21,780 lbs to set the tool, and keep the unloader seal closed.

WHEN ANNULUS PRESSURE IS GREATER THAN TUBING PRESSURE AT THE TOOL: 1.

Multiply the change in tubing pressure by Column 4. L1 = ΔP x Tubing Area Col. 4

2.

Multiply the change in annulus pressure by Column 5.



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Revision: H

WHEN ANNULUS PRESSURE SWABBING THE TUBING: 1.

IS

GREATER


THAN

TUBING PRESSURE

Page 11 of 26

AT THE

TOOL DUE

TO

Multiply the change in tubing pressure by Column 6. L1 = ΔP x Tubing Area Col. 6

2.

Multiply the change in annulus pressure by Column 7. L2 = ΔP1 x Annulus Area Col. 7 If the result is a force tending to open the unloader, and is greater than the original pack-off weight, additional set down weight is required. This additional weight is equal to the difference between the force tending to open the unloader and the required pack-off weight. If L1 + L2 < 0, the unloader valve tends to open. If L1 + L2 >0, the unloader valve tends to stay closed Be sure to consult slack-off charts to determine whether the requisite amount of pipe weight can be put on the tool. If slackoff weight is not sufficient, then drill collars may have to be used to put sufficient weight on the tool. Consult tubing movement simulation to insure that treating (tubing ballooning, thermal movement, etc.) does not remove too much of the initial pipe weight.

Example Problem 3



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9.6” 29.3-53.5 PPF TST-3 ASSEMBLY INSTRUCTIONS The 9.6” TST-3 Packer is configured to run in three weight ranges: 29.3-36ppf, 40-47ppf, and 47-53.5ppf. There are three sets each of gauge, guide, and spacer rings and two sets each of end and center elements. Identify the casing size, weight and element system to be used and dress the packer accordingly. Please refer to the 9.6” TST-3 Assembly Part Numbers (page 17) and Parts List (pages 18-21) for the correct parts for the different tool configurations. Check all parts for wear or damage. Replace any part that shows significant wear or other damage. All parts should be clean and free of rust. Remove any wrench marks with a file or emery cloth. Remove and discard any old or used rubber goods. Use only rubber goods that are within shelf life and storage requirements. Rubber goods must conform to BJ Specification 265203. Use only Downhole Tools approved thread and o-ring lubricants. See “Assembly Lubricants” section for approved lubricants. All threaded parts should make up smoothly. If not, have the parts inspected.

Tools Needed: • • • • •

3/16, 1/8 allen wrenches (ball end recommended), 2 pipe wrenches capable of gripping 2” pipe through 7” pipe, brass hammer (approx. 6 oz.), small pry-bar or punch (approx. 10” long and up to ½” dia.), 2 lb. dead blow hammer,



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Revision: H


Page 13 of 26

4.

Lubricate bypass seal (5) and install in bypass seal retainer (3).

5.

Slide bypass seal (5) and bypass seal retainer (3) over the top of the mandrel (7) until the bypass seal retainer (3) is close to the balance sleeve retainer (8). If the bypass seal (5) has become dislodged from the bypass seal retainer (3) push the bypass seal (5) back into position.

6.

Lubricate the O-ring groove on the top of the mandrel (7) and install the O-ring (18). Apply thread lubricant to the threads.

7.

Lubricate the seal area on the inside of the top sub (1-2). Screw the top sub (1-2) onto the mandrel (7) until it is hand tight. Back the top sub (1-2) off until the key slots in the top sub (1-2) line up with the key slots in the mandrel (7).

8.

Begin threading the bypass seal retainer (3) on to the top sub (1-2). When the bypass seal retainer (3) is near the key slots in the top sub (1-2), place the keys (4) in the slots. Be sure that the keys (4) seat fully. The tops of the keys (4) should be below the threads on the top sub (1-2). Finish screwing the bypass seal retainer (3) on. Make sure that the bypass seal (5) is properly positioned. Tighten the bypass seal retainer (3). Note: there may be a small gap on the OD where the bypass seal retainer (3) and the top sub (1-2) meet. This is acceptable, as the bypass seal retainer (3) is designed to shoulder on the ID to help hold the bypass seal (5). Remove any wrench marks with a file or emery cloth.

9.

Lubricate and install O-ring (20) in receptacle (10).

10. Apply thread lubricant to all threads on the receptacle (10). Measure the OD of the guide ring (12-14) and



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18. Make sure that the O-ring (22) is in place on the collet (35) and screw the collet (35) and element stack into place on the receptacle (10). Use Collet Assembly Tool (P/N 87694-1) to avoid damaging collet fingers during assembly or disassembly. Refer to the below illustration for assembly directions. Slide the Assembly Tool over the collet (35) fingers and tighten collet (35) by wrenching on Collet Assembly Tool body. When finished, remove Collet Assembly Tool before continuing with assembly of packer.



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destroy the carbide inserts. If a sliver of rubber was cut from the o-ring (21), or you suspect that the o-ring (21) was damaged, remove the button (17) inspect the o-ring (21). If the o-ring (21) is damaged, it must be replaced. 24. If necessary, rotate the button (17) such that the slot through the button (17) lines up with the slot on the receptacle (10) OD, and the flat faces on the carbide inserts face the bottom of the tool. 25. Prepare and install the button (17) next to this last one in the same manner as the first button (17). Again be sure that the O-ring (21) is in good condition, and the button (17) is oriented correctly. Check for shreds of rubber after installing each button (17). This is evidence of O-ring damage. Replace damaged O-rings immediately and re-install buttons (17) carefully. Persistent damage to O-rings at installation is evidence of bad installation practice or non-conforming buttons (17) or receptacle (10). 26. Place a spring (23) in each of the flat bottom holes in the bottom of the slot in the buttons (17). There should be two (2) springs (23) per button (17). 27. Place the piston retainer (16) strap in the slot in the receptacle (10) OD, covering the springs (23) in the buttons (17). Lubricate and secure in place with the countersunk socket head screws (15). 28. Repeat with the other three rows of buttons (17). 29. Lubricate the threads on the packer actuator body (40) and the cone (41-43) and screw together. 30. Stand the cone (41-43) and packer actuator body (40) vertically with the slots in the cone (41-43) pointing up. Hang the slips (44) in the slip retainer ring (46) and lower the slips (44) into the slots in the cone (41-43). 31. Lubricate the saddle ring groove on the slip retainer ring (46).



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45. Slide the dragblock (51) and springs (52) into the dragblock housing (50). Repeat for the other five (5) dragblocks (51). 46. Slide the j-housing (54-65) over the bottom sub (68-69). Align the slots in the j-housing (54-65) with the lug on the bottom sub (68-69) and slide the j-housing (54-65) over the j-lug on the bottom sub (68-69). Slide the drag block housing (50) down to meet the j-slot housing (54-65) and screw the two together. Note, this is a left-hand thread. Make tight and install the setscrews (53). Check the drag blocks (51) for free movement. 47. Rotate the J-housing (54-65) from the set position to the running position a couple of times to insure free movement of the dragblock housing (50) and J-housing (54-65). Move the J-slot to the setting position and push the assembly upward (toward the top sub (1/2)). Make sure that the slips (44) come out easily, and remain in the cone (41-43) and slip retainer (46). Pull J-housing (54-65) down (toward bottom sub (68-69)) firmly and make sure that the slips (44) stay in the cone (41-43). Move the J-slot back to the running position. Note: A guide ring (71) is not used on the 3-1/2” IF bottom sub (69).

48. Apply lubricant to the guide ring threads on the bottom sub (68-69). Slide the guide ring (71) on over the bottom sub (68) and thread onto the threads. Make tight and install the retaining setscrews (72). 49. Lubricate the threads on the bottom of the bottom sub (68-69) and install a thread protector. 50. Lubricate the box connection on the top sub (1-2) and install a thread protector . Note: This is sufficient only for indoor storage. If the tool is to be stored outdoors, appropriate measures must be taken to prevent corrosion of the mandrel (7) ID as well as the outer parts.



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9.6” TST-3 ASSEMBLY PART NUMBERS


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9.6” TST-3 PARTS LIST

Confidential Proprietary Information BJ Services Company, USA

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9.6” TST-3 ASSEMBLY VIEW


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9.6” TST-3 FISHING DIMENSIONS – 3-1/2” EUE 8 RD CONNECTIONS


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9.6” TST-3 FISHING DIMENSIONS – 4-1/2” IF CONNECTIONS


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2026 9.6 TST-3 Rev H

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