1.75-in.

OD Hydra-BlastTM Pro Tool

Assembly and Operating Instructions
Manual

Halliburton
Part No. 101241870
Hardcopy is uncontrolled

Table of Contents

Introduction .............................................................................................. 1

About This Manual ................................................................................... 3

Hydra-Blast™ Tool Theory and Equipment Considerations ....................... 3

CT Unit ................................................................................................ 4

Pump Requirements ............................................................................ 4

Wash Fluid .......................................................................................... 4

Friction Reduction ........................................................................... 4

Focusing Effect ............................................................................... 5

Macromolecular Bombardment ........................................................ 5

Suspension ..................................................................................... 5

Friction Reducers ................................................................................. 6

Laptop Computer with Hydra-Blast™ Software .................................... 6

Surface Filter ....................................................................................... 6

Downhole Inline Filter .......................................................................... 7

Recommended Bottomhole Assembly ................................................. 8

CT Connector .................................................................................. 8

Nozzle Head ................................................................................... 8

Job Modeling with the Hydra-Blast™ Software ........................................ 9

Overview ............................................................................................. 9

General Information Screen ............................................................... 10

Hydra-Blast™ Parameters Screen ..................................................... 11

Coiled Tubing ................................................................................. 12

Hydra-Blast™ Tool ......................................................................... 12

Cleaning Energy ........................................................................ 12

Tool Pressure Loss ................................................................... 13

Hydra-Blast™ Pro Option .......................................................... 13

Jet Head OD ............................................................................. 14

Number of Passes .................................................................... 14

Well Information ............................................................................ 14

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Table of Contents

Know Jet Head .............................................................................. 15

Know Pump Pressure .................................................................... 15

Output Screen ................................................................................... 16

Optimum Nozzle Jet Design ......................................................... 16

Error Messages ................................................................................. 17

Best Practices ....................................................................................... 18

Jobsite Procedures and Inspections ...................................................... 18

Post-job Maintenance Procedures ......................................................... 19

Disassembling the Hydra-Blast™ Pro Tool ........................................ 20

Disassembling and Reassembling the Double Joint .......................... 27

Removing and Replacing Bearings .................................................... 29

Transmission Housing ................................................................... 29

External Torque Transmitter Gear and Ring Gear ........................... 30

Top Driveshaft Extension .............................................................. 31

Bottom Cap ................................................................................... 32

Assembling the Hydra-Blast™ Pro Tool ................................................. 32

Oil Filling Instructions ............................................................................ 42

Cutting Tubing with the Hydra-Blast™ Pro Tool ...................................... 45

Job Information ................................................................................. 46

Equipment ......................................................................................... 46

CT Unit .......................................................................................... 46
Pumping Unit ................................................................................ 46

Holding Tank for Gelled Fluid and Blender ..................................... 46

Gelled Fluid ................................................................................... 47

Cutting Material ............................................................................. 47

Laptop Software/Spreadsheet Cutting Job Design ........................ 47

Downhole Tools ............................................................................. 49

PreJob Procedures ............................................................................ 50

Recommended Job Procedures ......................................................... 51

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Table of Contents

Job Completion Procedures .............................................................. 52

Appendix A—Cleaning-Head Examples ................................................. 53

Appendix B—Cutting-Head Examples ................................................... 55

Guidelines for Designing Cutting Heads ............................................. 55

Appendix C—Spare Parts Lists ............................................................. 56

Appendix D—Hydra-Blast™ Tool Cutting Sample Calculation ................ 57

Appendix E—”Cutting Tubing with the Hydra-Blast™ Pro Tool” ............... 58

Cutting Tubing with the Hydra-Blast™ Pro Tool .................................. 59

Hydraulic Calculations ................................................................... 59

Coiled Tubing Friction ..................................................................... 60

Hydrostatic Pressure on Tubing/Casing Annulus ........................... 60

Sieve Analysis of Cutting Material ................................................ 60

Displacement Fluid ........................................................................ 60

Fluid Level .................................................................................... 61

Job Execution ............................................................................... 61

Cutting Nozzles Size ..................................................................... 61

Use a “Stop” .................................................................................. 62

Centralization ................................................................................ 62
Additional Things to Remember ..................................................... 62

1.75-in. Hydra-Blast™ Pro Tool (698.25200) Drawing ............................. 63

1.75-in. Hydra-Blast™ Pro Tool (698.25200) Parts List and Notes ......... 63

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All information contained in this publication is confidential and proprietary

property of Halliburton Energy Services, Inc. Any reproduction or use of
these instructions, drawings, or photographs without the express written
permission of an officer of Halliburton is forbidden.

© 2006 Halliburton
All Rights Reserved. Printed in the United States of America.

Part No. 101241870

Printing History:
First Release (July, 2001)
Second Release (July, 2003)
Third Release (October, 2006)

iv
1.75-in. OD Hydra-BlastTM Pro Tool

Assembly and Operating Instructions Manual

SAP No. 101241870

Introduction
The 1.75-in. OD Hydra-Blast™ Pro tool is used in conjunction with coiled tubing (CT) for
removing scale and other organic buildup from the ID of casing or tubing. The tool’s cleaning
head rotates at a constant rate, that is controlled by the flow rate of the cleaning fluid being
pumped down the CT, thereby allowing complete cleaning coverage in only one pass. The
cleaning speed of the tool is determined by the Hydra-Blast™ computer program.
The vertical travel rate of CT using the Hydra-Blast™ Pro tool depends on the material
being removed, the number of jets in the nozzle head, the flow rate of the cleaning fluid,
the pressure drop across the jets, and the ID of the surface being cleaned. Typical vertical
travel rates range from 3 to 10 ft/min.
The 1.75-in. Hydra-Blast™ Pro tool is designed to operate in any tubing or casing. How-
ever, the maximum flow rate through the tool limits its effectiveness in casing or tubing
with an ID greater than 7-in. Additionally, when the tool is used with larger casing, side
loading can damage the tool’s output shaft.
In addition to cleaning, the Hydra-Blast™ Pro tool is capable of cutting pipe when sand is
mixed with the fluid being pumped.
The following fluids can be pumped through the Hydra-Blast™ Pro tool:
• Water
• HCl acid
• Turpine
• Acetic acid
• Nitrogen foams

October 2006 1.75-in. OD Hydra-BlastTM Pro Tool 1

 A 50-quality foam is recommended as the upper limit of a nitrogen mixture pumped
through the Hydra-Blast™ Pro tool. If HCl acid enters the tool’s oil chamber, the bearings
can be damaged. Aromatic solvents, such as xylene, should not be used with the Hydra-
Blast™ Pro tool.
The 1.75-in. OD Hydra-Blast™ Pro tool is available with two different top thread connec-
tions. Table 1 provides part numbers for each option. Table 2 provides tool specifications,
and Table 3 provides part numbers for redress kits and replacement/optional parts.

Table 1—Hydra-Blast™ Pro Tool Versions

Tool Version SAP Part No.
1.315-in. OD, 2.25-lb/ft 100071267
OECO "A" upper thread
1 1/4-in. AMMT upper thread 101208071

Table 2—Hydra-Blast™ Pro Tool Specifications

Temperature rating (standard stator) 250°F
Temperature rating (high-temperature stator) 350°F
Maximum pressure rating 6,300 psia
Maximum flow rate through tool 50 gal/min
Rotational speed at 42 gal/min 20 rev/min
Maximum tensile rating (in retaining ring) 5,200 lb SF (4)
Maximum tensile rating (in rest of tool) 20,600 lb
a
Differential pressure through the stator

Table 3—Replacement Kits and Parts

Description SAP Part No.
Seal redress kit 101206467
Bearing redress kit 101216034
Replacement stator for 250°F, 100071270
0.000-in. oversize
Optional stator for 300°F, 101207062
0.020-in. oversize
Optional stator for 350°F, 101207063
0.030-in. oversize

2 1.75-in. OD Hydra-BlastTM Pro Tool October 2006

About This Manual
This manual contains the following information about the Hydra-Blast™ Pro tool:

• Introduction (Page 1)

• Hydra-Blast™ Tool Theory and Equipment Considerations (Page 3)

• Job Modeling with the Hydra-Blast™ Software (Page 9)

• Best Practices and Jobsite Procedures and Inspections (Page 18)

• Postjob Maintenance Procedures (Page 19)

• Disassembling the Hydra-Blast™ Pro Tool (Page 20)

• Disassembling and Reassembling the Double Joint (Page 27)

• Removing and Replacing Bearings (Page 29)

• Assembling the Hydra-Blast™ Pro Tool (Page 32)

• Oil Filling Instructions (Page 42)

• Cutting Tubing with the Hydra-Blast™ Pro Tool (Page 45)

• Appendix A—Cleaning-Head Examples (Page 53)

• Appendix B—Cutting-Head Examples (Page 55)

• Appendix C—Spare Parts Lists (Page 56)

• Appendix D—Hydra-Blast™ Tool Cutting Sample Calculation (Page 57)

• Appendix E—”Cutting tubing with the Hydra-Blast™ Pro Tool” (Page 58)

• 1.75-in. Hydra-Blast™ Pro Tool (698.25200) Foldout, Parts List and Notes (Page 63)

Hydra-Blast™ Tool Theory and Equipment Considerations

Cleaning operations performed with the Hydra-Blast™ Pro tool are similar to those
performed with the original Hydra-Blast™ indexing tool. A pressure drop occurs when
fluid passes through nozzles situated at various locations on the cleaning head. (See
“Optimum Nozzle Jet Design,” Page 16). This pressure drop creates the high fluid
forces necessary for removing the various materials that accumulate on the inside of the
casing or tubing. Software is available for calculating the pressures, flow rates, and CT
travel speeds that can provide optimal cleaning. See “Job Modeling with the Hydra-
Blast™ Software,” (Page 9) for more information.
The materials and equipment necessary for performing cleaning operations with the
Hydra-Blast™ Pro tool are described on the following page.

October 2006 1.75-in. OD Hydra-BlastTM Pro Tool 3

 CT Unit
Any Halliburton CT unit is appropriate for Hydra-Blast® service. Pump pressures will be
near 5,000 psi. Because the efficiency of the cleaning job depends on the number of
orifices and the pressure drop across them, you should use the shortest CT string possible.
To help achieve one-pass cleaning, use a CT unit capable of maintaining a steady speed
of 1 to 10 ft/min while running CT into the hole. A high-pressure CT unit will allow
removal of harder materials and larger tubing/casing IDs.

Pump Requirements
Pump’s such as an HT-150™ or HT-400™ can be used for jet cleaning operations. Volume
requirements will vary from 20 to 50 gal/min. When a filter polymer injection skid is used,
the polymer is mixed with the wash water as the water passes through the skid. If a filter
polymer injection skid is not used, circulating tanks are required for mixing the polymer.
During land jobs, wash water is usually pumped directly from a vacuum truck. During
offshore and inland water jobs, a mixing or holding tank is required.

Wash Fluid
Tests have shown that a 0.3% polymerized freshwater solution removes scale 10 to 50
times more effectively than water alone. The advantages of polymerized freshwater
solutions follow.

Friction Reduction
Tests have shown that mixing polymer with water allows 57% more fluid to be pumped
than using fresh water alone. The friction or drag reduction allows more fluid to reach the
cleaning head with the same pump pressure, thus increasing the amount of work per-
formed. Figure 1 illustrates that adding a friction reducer can increase flow rate.
35

30 Water with
Polymer
Flow Rate, gal/min

Water
25

20

15

10
1,000 2,000 3,000 4,000 5,000
Pressure, psi

Figure 1—Benefit of friction reducer for flowrate

4 1.75-in. OD Hydra-BlastTM Pro Tool October 2006

 Focusing Effect
The jet stream remains more focused in polymer solutions than in water alone. This
focusing effect decreases the jet power loss as the distance from the jet to the target
(standoff) increases. This effect is especially important during cleaning of casing or liners
located below the production tubing. Figure 2 shows how the jet remains more focused in
a solution containing a friction-reducing polymer.

Jet using only water

Jet with polymer

Figure 2—Focusing effect of friction reducer

Macromolecular Bombardment
The high molecular weight and strength of the polymer causes the jet stream exiting the
orifices of the tool to strike the target with more force than water alone. Figure 3 com-
pares the effectiveness of water and polymerized water cutting through a material.

Water only

Polymer water

Figure 3—Benefits of polymer for cutting a material

Suspension
A 0.3% polymer freshwater solution will maintain fines and solids in suspension much
more effectively than water alone, allowing the cuttings to be circulated out as they are
blasted loose.

October 2006 1.75-in. OD Hydra-BlastTM Pro Tool 5

 Friction Reducers
The following friction reducers are recommended for use with the Hydra-Blast® service:
• Halliburton’s FR-26LC™, which contains fresh water and 2% KCl (not recommended
for calcium environments)
• Nalco’s WFR-11™, which is similar to FR-26LC
• Berkley Chemical Company’s Superwater™, which contains fresh water and light
brines
• N.J. Drilling Fluids’ Kezlan XCD™, which contains fresh water and brines
• Halliburton’s FR-28LC™, which contains fresh water and brines
• Halliburton’s SGA-HT®, which contains brines and acid and is used for high-tempera-
ture applications
• Kelco’s KOD-85™, which contains fresh water and brines
Most polymers are mixed with fluid at a concentration of 0.3% by volume. Consult the
manufacturer data sheet for recommended concentrations that will achieve maximum
friction reduction.

Laptop Computer with Hydra-Blast™ Software

The Hydra-Blast™ software program can be downloaded from the following HalWorld
site:
http://halworld.corp.halliburton.com/hes/hestch/HESTCH_ts/HESTCH_ts_productsDfw/Outright/
HESTCH_ts_Outright_downloads.asp

Note You must obtain a site key from this address. After you log on, instructions will be
provided for obtaining a site key.

Surface Filter
The fluid used for removing materials from the casing usually contains undesirable solids
and trash before it washes the material from the casing. Therefore, a low-pressure filter
should be used in the pump’s suction line. The filter element should be 40- to 50-micron
rated with a capacity of up to 60 gal/min. Because the filter is located in the pump’s
suction line, the pressure drop across the filter at the maximum flow rate should be 5 psi
or less.
A high-pressure inline filter (Figure 4, Page 7) has also been designed for the pump
discharge line, allowing fluid to be filtered before it enters the reel. This filter has a slot
screen that is 0.040 in. wide located inside a 2- or 3-in. pup joint. This filter often
eliminates the need for a trip out of the hole to clean the downhole inline filter. Table 4
(Page 7) lists the part numbers of various inline filters.

6 1.75-in. OD Hydra-BlastTM Pro Tool October 2006

 CCD0089
Figure 4—High-pressure inline filter

Table 4—Surface Inline Filters

SAP Part No. Description
100071305 Inline filter, 2-in. 1502 Weco with 0.040-in. screen
100012591 Replacement filter screen for the 2-in. inline filter
100071306 Inline filter, 3-in. 1502 Weco with 0.040-in. screen
100071307 Replacement filter screen for 3-in. inline filter

Downhole Inline Filter

Because the orifices or jets in the cleaning tool are small (0.040- to 0.090-in. diameter),
the cleaning fluid must be free of particles that might plug or erode the orifices. The
inline filter has a 0.020-in. slot with a screen that is run above the slowly rotating Hydra-
Blast™ Pro tool. This filter is the last mechanism used to prevent rust scale, sand, and mill
scale left in the CT from previous jobs from entering the tool and plugging or eroding the
jets. Table 5 lists part numbers for the filter and replacement filter.

Table 5—Downhole In-line Filter

SAP Part No. Description
100070963 Downhole filter, 1.69-in. OD, 0.020-in. slot width;
1.315-in. OD, 2.25-lb/ft OECO "A" threads
100070964 Replacement filter for 1.69-in. downhole filter

October 2006 1.75-in. OD Hydra-BlastTM Pro Tool 7

 Recommended Bottomhole Assembly
Table 6 provides SAP numbers for tools commonly included in the bottomhole assembly
for Hydra-Blast™ tool operations. For more information about these tools, refer to the
Coiled Tubing Tools Manual (Part No. H00949, SAP No. 101335389), available on the
HalWorld website at:
http://halworld.corp.halliburton.com/hes/hesps/hespspe/hespspe_CT/hespspe_CTT/
hespspe_CTT_manuals/hespspe_CTT_manuals_content/
hespspe_ctt_manuals_h00949.asp
For information about the CT connector and the nozzle head, which are also part of the
recommended bottomhole assembly, see the following subsections.

Table 6—Recommended Bottomhole Assembly

SAP Part No. Description Connection
100070716 1.75-in. OD double-flapper check valve 1.315-in. OD 2.25-lb/ft OECO "A" box x pin
100004086 1.81-in. OD hydraulic disconnect 1.315-in. OD 2.25-lb/ft OECO "A" box x pin
100070798 1.75-in. OD ball-drop circulating valve 1.315-in. OD 2.25-lb/ft OECO "A" box x pin
100070842 1.81-in. OD rupture disc sub 1.315-in. OD 2.25-lb/ft OECO "A" box x pin
100071267 1.75-in. OD H-B Pro tool 1.315-in. OD 2.25-lb/ft OECO "A" box x pin
101317673 1.75-in. OD motorhead 1.25-in. OD CT connector x 1.00-in. AMMT pin
101353530 1.75-in. OD motorhead 1.00-in. AMMT box x pin

CT Connector
Refer to Section 2 of the Coiled Tubing Tools Manual for the appropriate CT connector.
If available, use a 1.315-in. OD, 2.25-lb OECO “A” pin thread.

Nozzle Head
The Hydra-Blast™ program calculates the number of jets and speeds required for clean-
ing the entire target surface. Nozzle heads with different ODs are available for changing
job conditions. The OD of a cleaning nozzle should be at least four jet diameters and no
more than 60 jet diameters from the target ID. The jets are drilled in the nozzle head as
required for each job. Follow these guidelines for nozzle placement:

• For wall-cleaning operations (side-blasting), design the nozzle head with three vertical
rows of an equal number of jets. Place the jets 120° apart with 0.25-in. spacing. Drill
an additional four jets on the nozzle face.

• For cutting bridged or solid materials (down-blasting), drill most of the jets on the
nozzle face with equal spacing. Side jets should be equally spaced on three vertical
rows to help centralize the tool.

8 1.75-in. OD Hydra-BlastTM Pro Tool October 2006

Job Modeling with the Hydra-Blast™ Software
In this section, the functions of the Hydra-Blast™ software are described. You will learn
how to enter the proper information into the correct screens

Overview
The Hydra-Blast™ computer program can be used for designing cleaning jobs for the
indexing tool or the Hydra-Blast™ Pro tool. The new Hydra-Blast™ program is a Win-
dows-based software package that replaces the old “Blast” program. It also includes the
code necessary for accommodating the rotational features of the Hydra-Blast™ Pro tool or
the indexing feature of previous Hydra-Blast™ indexing tools. To use this program with
the Hydra-Blast™ Pro tool, check the Hydra-Blast™ Pro box. To use this program with
the indexing tool, leave the box unchecked.
Unlike the old Blast program, the new Hydra-Blast™ program allows you to (1) enter the
number and size of the jets and the required pressure drop across the jets and (2) receive
output for flow rate and pump pressure. This option is referred to as the “know jet head”
option. The “know pump pressure” option determines the required number and size of jets
and the pressure drop across the jets when the pump pressure and flow rate (optional) is
entered.
To activate the Help/Hints option for the input boxes, find the icon bar, located at the top
of the screen. Click on the help icon, which appears as a balloon containing a question
mark, to turn this option on or off (Figure 5, Page 10). The question mark is blue when
the help option is turned on and gray when the help option is off.
To save the input file for the job you are modeling, select File<Save or File<Save As from
the File menu. You can also open saved input files from this menu. The results can be saved
as a Word document or printed on a printer. To print or save an output file, click the Reports
icon under the Forms menu on the left side of the screen.

October 2006 1.75-in. OD Hydra-BlastTM Pro Tool 9

 General Information Screen
The General Information screen allows users to enter well information. None of this
information is used for calculations; it is used for reporting purposes only. Figure 5 shows
an example job entered on the General Information screen.

Figure 5—General Information screen

10 1.75-in. OD Hydra-BlastTM Pro Tool October 2006

 HydraBlast™ Parameters Screen
You can change the program’s input and output units from the HydraBlast™ parameters
screen (Figure 6). From the Tools menu, select Change Units. The HydraBlast™
Parameters window opens. From this window, you can change parameters for the CT or
the HydraBlast™ tool. You can also change well information and enter data for the jet
head or the pump that will be used.

Figure 6—HydraBlast™ Parameters screen

October 2006 1.75-in. OD Hydra-BlastTM Pro Tool 11

 Coiled Tubing
From the HydraBlast™ Parameters window, you can change the following CT param-
eters:
• Outside diameter—CT outside diameter (OD, in.)
• Wall thickness—CT wall thickness (in.)
• Safe Pressure—maximum pump pressure allowed on CT (psi)
• Core Diameter—core diameter of the CT reel (in.)
• Length—length of CT on the reel (ft)
• Fluid Density—density of the cleaning fluid (lb/gal)

Hydra-Blast™ Tool
From the HydraBlast™ Parameters window, you can change the following tool param-
eters (Figure 7):

• Cleaning energy

• Tool pressure loss

• Tool selection (Hydra-Blast™ Pro tool or Indexing tool)

• Jet head OD

• Number of passes

Figure 7—Hydra-Blast™ Tool parameters dialog on the HydraBlast™ Parameters window

Cleaning Energy
The required cleaning energy of the tool relates to the relative hardness of the scale. It is a
dimensionless number and is not the same as compressive strength. Scale samples can be
analyzed for accurate identification. Table 7 (Page 13) lists the required tool cleaning
energy for various scale materials.

12 1.75-in. OD Hydra-BlastTM Pro Tool October 2006

 Table 7—Required Cleaning Energies
for Various Scale Materials
Scale Required
Material Cleaning Energy
Barium sulfate 7,000 psi
Silicate 6,000 psi
Calcium carbonate 5,500 psi
Calcium sulfate 4,500 psi
CO3/SO4/Si complexes 3,800 psi
Water scale with hydrocarbons 3,200 psi
Coal tar 3,000 psi
Coke and complexes 2,500 psi
Wax and complexes 2,000 psi
Paraffin 1,200 psi
Sludges 1,000 psi
Mud, gel, etc. 800 psi
Semi-liquid materials 500 psi

Tool Pressure Loss

Tool pressure loss refers to the pressure lost through the cleaning tool itself. This unit
does not include pressure loss through the tubing or across the nozzles. The recommended
pressure-loss value for the 1.75-in. OD Hydra-Blast™ Pro tool is 1,000 psi at a flow rate
of 1 bbl/min. The recommended pressure loss through the 1.60-in. OD Hydra-Blast™
indexing tool is much lower (300 psi). You can check this value by performing a surface
test without the nozzle on the tool. Connect the tool to the pump to eliminate any friction
pressure in the CT.

Hydra-Blast™ Pro Option

Check this box only if you are using the Hydra-Blast™ Pro tool. To enter additional tool
information, click on the Input box. A window will appear in which you can enter rota-
tional speed and side-jet spacing.
• Rotational Speed. The normal tool speed is 20 rev/min. Rotational speed can
be tested in the shop for each tool and pump rate. The tool’s rotational speed
may be higher or lower than 20 rev/min depending on the stator/rotor combina-
tion used. To determine rev/min, consult Table 8 (Page 14).
• Side-Jet Spacing. This is the vertical spacing between the side jets on the
cleaning head. The optimum spacing should be 0.25 in. This value is used for
calculating the speed at which the CT can be cleaned, depending on the number
of side jets used.

October 2006 1.75-in. OD Hydra-BlastTM Pro Tool 13

 Table 8—Various Flow Rate Outputs
Flow Rate Speed Pressure
(gal/min) (rev/min) (psi)
20 10 350
30 15 700
40 20 1,000
50 22 1,500

Jet Head OD
Several cleaning heads are available for the Hydra-Blast™ tools. Table 9 shows the heads
available for small tools. The SAP numbers in the table are for heads that are blank
(without nozzles). Nozzles are drilled at the local level.

Table 9—Cleaning Heads for

Through-Tubing Hydra-Blast™ Tools
Jethead
SAP Part No.
Size (in.)
1.60 100071224
1.75 100071225
1.90 101002418
2.00 100071226
2.16 101002419
2.30 101002420
2.60 101002421
2.75 101002422

Number of Passes
Use only one pass for the Hydra-Blast™ Pro tool. Multiple passes are necessary for
indexing tools. The total number of required passes depends on the nozzle pattern on the
cleaning head.

Well Information
From the Hydra-Blast™ Parameters window, enter the following well information:
• Target ID. This is the ID of the pipe to be cleaned.
• Max Work Depth. This is the maximum depth of the pipe section to be cleaned.
• Pressure at Depth. This is the bottomhole pressure at the maximum work depth.
This pressure can change during the job. Use the maximum expected bottomhole
pressure during the job.
• Bottom Temp. This value is not used in any calculation. It is necessary for
determining whether the temperature limit of the stator is being exceeded.
• Work Interval. This is the length of pipe section to be cleaned.
• Min Annulus Vel. This is the minimum annular velocity required for lifting
debris out of the well. Generally, 75 ft/min is an appropriate annular velocity.

14 1.75-in. OD Hydra-BlastTM Pro Tool October 2006

 Know Jet Head
At this portion of the Hydra-Blast™ Parameters window, you will have to decide
whether you want to enter data about the jet head or the pump that will be used. Nor-
mally, you will select Know Jet Head. Iteration of the jet helps optimize cleaning
efficiency. From this portion of the window, you will enter the following information:
• Drill Size. This is the diameter of the drill used for drilling the nozzles in the jet
head. The smallest recommended drill size is 0.040 in. Smaller drill bits can
break easily. Table 10 lists available drill sizes.
• P-loss Across. This is the pressure drop across the nozzles. A higher pressure-
drop value will increase cleaning efficiency. The normal pressure-drop value is
between 2,500 and 3,500 psi unless you are using a high-pressure unit or remov-
ing soft material from the pipe.
• Number Used. This is the number of jets used. Normally, between 10 and 22 jets are
used with the Hydra-Blast™ Pro tool. These numbers assume that four jets are used
for down-blasting, and the rest are used for side-blasting.

Table 10—Available Drill Sizes (in.)

0.0400 0.0595 0.0785 0.0995
0.0410 0.0625 0.0810 0.1015
0.0420 0.0635 0.0820 0.1040
0.0430 0.0670 0.0860 0.1065
0.0465 0.0700 0.0890 0.1093
0.0469 0.0730 0.0935 0.1100
0.0520 0.0760 0.0960 0.1110
0.0550 0.0781 0.0980 0.1130

Know Pump Pressure

If you decide to enter data about the pump that will be used, enter the following infor-
mation:
• Pump Pressure. This is the surface pump pressure required during the job.
• Pump Rate. This is the flow rate from the pump. This field is optional. If left
blank, the program will still calculate correctly.

October 2006 1.75-in. OD Hydra-BlastTM Pro Tool 15

 Output Screen
The Output screen (Figure 8) shows a Results Display for a successful job in the lower
portion of the screen.

Optimum Nozzle Jet Design

Speed<100% is the maximum vertical speed at which an individual jet can travel and still
remove scale. Speed-Full ID is the maximum vertical speed at which the jet can travel
while still providing complete pipe coverage. An optimum nozzle jet design is one in
which the Speed<100% and Speed-Full ID are very similar. The lower speed is recom-
mended as the true travel speed for the CT. The Speed<100% value should be slightly
higher than the Speed-Full ID value, providing a conservative nozzle design. However,
the speeds should be within 10 ft/min of each other. This arrangement can prevent the
loss of any cleaning potential, which can increase job time.
Generally, the software will provide a solution in which the Speed<100% value is much
higher than the Speed-Full ID value. To achieve more similar cleaning speeds, reduce the
pressure drop across the jets, reduce the jet size, and increase the number of nozzles.
Increasing the number of jets will increase the Speed-Full ID. Reducing the pressure drop
and/or jet size will decrease the Speed<100%. To decrease Speed-Full ID and increase
Speed<100%, increase the pressure drop across the jets, increase the jet size, and reduce
the number of nozzles.

Figure 8—Output screen

16 1.75-in. OD Hydra-BlastTM Pro Tool October 2006

 Error Messages
When the program provides a solution that will clean the pipe, a balloon will appear on
the screen with the following message: “This design will successfully remove scale
buildup.”
If the program calculates a solution that will not remove scale or exceeds some input limits,
an error message will be displayed in the balloon. In this case, you will need to iterate to
find the best solution. Normally, changing the number and size of jets and the pressure drop
across the jets will provide a better solution. Figure 9 shows a typical error message.

Note Notice that no values appear in the Results Display when the program gives an error message.

Figure 9—Output screen showing typical error message

October 2006 1.75-in. OD Hydra-BlastTM Pro Tool 17

Best Practices
These best practices should be used for every Hydra-Blast™ Pro tool cleaning job:

• Always use the computer program for designing the job before it is run.

• Always use polymer fluid for cleaning operations.

• Ensure that the standoff distance remains within acceptable limits.

• Run and pull the tool through the target area at the speed calculated by the software.

• If possible, run a full-size dummy cleaning tool through the target area on wireline
before the job.

• Collect accurate bottomhole pressure data.

• Check the diameter of the nozzle orifices after every run. You can use a drillbit as a gauge.

• Before each run, perform a surface check to ensure that the tool rotates properly.

• Check and clean the filter elements after every job.

• For cleaning operations, use clean fluid with at least 50-micron filtration.

• When removing barium sulfate or other hard materials, circulate the polymerized fluid
one time only.

Jobsite Procedures and Inspections

At the jobsite, perform the following procedures and inspections before beginning the job:

1. Circulate the CT with clean fluid before attaching the Hydra-Blast™ Pro tool. This
procedure cleans the CT and allows pressures and rates to be recorded during the job.

2. Attach the Hydra-Blast™ Pro tool to the CT, and pump cleaning fluid through the tool
to ensure proper rotation.

3. Attach the CT injector to the wellhead. Be sure not to set any weight on the tool nozzle.

4. Slowly begin running the tool in the hole until it has passed all surface equipment and
is inside the tubing/casing.

5. Pump fluid through the Hydra-Blast™ Pro tool to ensure that it is still rotating.

6. Flush the tool with fresh water immediately after each job.

Caution Tool damage may occur if the tool is not redressed immediately after each job.

18 1.75-in. OD Hydra-BlastTM Pro Tool October 2006

Post-job Maintenance Procedures
This section provides instructions for performing the following post-job procedures:

• Disassembling the Hydra-Blast™ Pro Tool (Page 20)

• Disassembling and Reassembling the Double Joint (Page 27)

• Removing and Replacing Bearings (Page 29)

These procedures will help prolong tool life and may help ensure operational accuracy.
Table 11 lists the recommended hand tools for performing maintenance operations on the
Hydra-Blast™ Pro tool.

Caution Never reuse the Hydra-Blast™ Pro tool unless it has been completely redressed. If
the tool is not redressed and refilled with oil, gears can become damaged.

Table 11—Recommended Hand Tools

and Special Equipment for Tool Maintenance
Description Qty. Ordering Information
18-in. Pipe wrench 2 Local purchase
5
/8-in. Open-end wrench 1 Local purchase
Small, flat-blade screwdriver 2 Local purchase
1
/4-in. Hex wrench 1 Local purchase
3
/16-in. Hex wrench 1 Local purchase
a
O-ring 1 Local purchase
1
/8-in. Flat punch 1 Local purchase
Adjustable pliers 1 Local purchase
Small hammer 1 Local purchase
Adjustable 12- or 14-in. wrench 1 Local purchase
High-temperature thread grease 1 Local purchase
Large flat-blade screwdriver with square blade 1 Local purchase
Bearing replacement/rotor positioner tool 1 Duncan (SAP No. 101246099)
Martin Decker hand pump 1 Duncan (SAP No. 100081057)
Retaining ring pliers 1 Local purchase
Wood dowel rod 1 1/8-in. OD × 24-in. long 1 Local purchase
a
Always apply a thin coat of grease to all threads and O-rings before assembly.

October 2006 1.75-in. OD Hydra-BlastTM Pro Tool 19

 Disassembling the Hydra-Blast™ Pro Tool
To disassemble the Hydra-Blast™ Pro tool, perform the following steps:

1. Place the assembly in a vise, and grip down on the top sub (Figure 10).

Caution Do not grip down on the stator. Housing damage could result.

2. Remove the cleaning head from the cleaning nozzle clutch sub adapter (Figure 11).
Remove the clutch sub adapter, split ring, and clutch sub (Figures 12 and 13).

Figure 10 Figure 11

Figure 12 Figure 13

3. Remove the pipe plugs from the transmission housing and the bottom cap (Figures 14
and 15). Oil will be lost from the transmission housing; therefore, use a bucket to
contain the oil.

20 1.75-in. OD Hydra-BlastTM Pro Tool October 2006

Figure 14 Figure 15

4. Unscrew the bottom cap (left-hand threads) from the transmission housing. Hold a
backup wrench on the output driveshaft to avoid applying torque on the gears (Figures
16 and 17).

Figure 16 Figure 17

5. Remove the bottom cap from the output drive shaft. If the thrust bearing and thrust
washers remain in the bottom cap, remove them and set them aside on a clean surface
(Figure 18).

6. Pull the output driveshaft and top driveshaft extension from the transmission housing
and the camshaft. Remove the thrust bearing and the thrust washers from the
driveshaft, and set them on a clean surface (Figure 19).

Figure 18 Figure 19

October 2006 1.75-in. OD Hydra-BlastTM Pro Tool 21

 7. Place the top driveshaft extension in a vice, gripping on the flats. Be careful not to
damage the bearing surfaces (Figure 20).

8. Use a wrench on the flats of the output driveshaft and remove from the top driveshaft
extension (Figures 21 and 22).

9. Remove the Polypak® seal and discard it (Figure 23).

10. Remove the bearings from the top driveshaft extension and set them aside.

Figure 20 Figure 21

Figure 22 Figure 23

11. Remove the transmission housing from the double-joint extension housing. Be careful
not to drop the gears as they slide out of the transmission housing (Figure 24).

12. Turn the housing upward, and slide the bearing and gear sections from the housing
(Figure 25).

22 1.75-in. OD Hydra-BlastTM Pro Tool October 2006

Figure 24 Figure 25

13. Separate all parts of the transmission and set them aside for inspection (Figure 26).
The small bearings in the torque transmitter gear will slide out. Remove them and set
them aside (Figure 27). Refer to “Removing and Replacing Bearings” (Page 29) for
instructions for removing other bearings. All bearings should be removed and closely
inspected. Replace worn or damaged bearings.

Figure 26 Figure 27

14. Remove the washers and threaded bronze bearing from the transmission camshaft
(Figures 28, 29, and 30).

Figure 28 Figure 29

October 2006 1.75-in. OD Hydra-BlastTM Pro Tool 23

Figure 30 Figure 31

15. Remove the double-joint extension housing from the stator (Figure 31).

16. Remove the floating piston from the double-joint extension housing. Remove by
carefully tapping the piston out with a 1 1/8-in. OD wood dowel or soft metal rod
(Figure 32).

17. Remove the Polypak seal from the piston ID (Figure 33) and the O-rings from the
piston OD. Check for any unusual wear or scarring on the piston or the camshaft.
Because the piston floats on the camshaft, the camshaft must be smooth. Repair or
replace worn or scarred parts.

Figure 32 Figure 33

24 1.75-in. OD Hydra-BlastTM Pro Tool October 2006

 18. Inspect the ID ends of the housing to determine which end seals the piston
(Figure 34). The sealing area of the piston OD must be smooth for approximately
6 in. Both ID ends of the housing are identical, but only one end seals the piston.
Always use the best end for piston sealing.

19. Remove the camshaft from the flow adapter using the wrench flats on the camshaft,
and insert a 1/4-in. rod in the flow adapter holes to hold the adapter stationary
(Figure 35).

20. Remove the rotor from the stator by simultaneously rotating the double joint to the right
and pulling it out. When the rotor begins exiting the end of the stator, you can use a
wrench on the flats of the rotor to help rotate the rotor (Figures 36 and 37).

Caution Rotate the joint to the right; otherwise, the double joint will unscrew from the rotor.

Figure 34 Figure 35

Figure 36 Figure 37

October 2006 1.75-in. OD Hydra-BlastTM Pro Tool 25

 21. Remove the double joint from the rotor (Figure 38).

Note You will need to remove and inspect the pins in the double joint before reassembling the
tool. Refer to “Disassembling and Reassembling the Double Joint” (Page 27).

22. Remove the flow adapter from the double joint, making sure not to damage the parts
(Figure 39). If necessary, insert a 1/4-in. rod in the flow adapter holes to unscrew it.

Figure 38 Figure 39

23. Remove the stator from the top sub. Place the wrench 3 to 4-in. from the end of the
stator so that a crushing load is not applied to the threads on the ID. The threaded ends
are very thin and can be damaged easily (Figure 40).

24. Inspect the ends of the stator for erosion around the area where the flow enters and
exits the rubber. This area is susceptible to high turbulence. Inspect the rubber for
flaking. Replace damaged stators (Figure 41).

25. Inspect the rotor to ensure that the nickel plating is not flaking. Replace damaged or
worn rotors.

Figure 40 Figure 41

26 1.75-in. OD Hydra-BlastTM Pro Tool October 2006

 Disassembling and Reassembling the Double Joint
To disassemble the double joint, perform the following:

1. Place one end of the double joint in a vise. Support the joints rigidly with the small-
diameter pin in the vertical position and the lock ring facing up (Figure 42). Use a punch
to tap out the small pin, being careful not to lose the lock ring in the recess of the center
block (Figure 43). Repeat this procedure with the other end of the double joint.

Figure 42 Figure 43

2. Remove the lock ring from the double joint and set it aside (Figure 44).

3. Position the double joint in the vise to access the oiler pin. Tap out the pin, making
sure not to damage the pin’s oil port (Figure 45).

Figure 44 Figure 45

October 2006 1.75-in. OD Hydra-BlastTM Pro Tool 27

 4. Inspect all parts of the double joint, paying close attention to the thin area of the large
pin. Replace the pin if it is damaged or worn (Figure 46).

5. Reassemble the joint in reverse order, making sure the lock ring is in place.

6. Coat the oil port on the large pin with a spray lubricant. Ensure that the joint swivels
freely (Figure 47).

Figure 46 Figure 47

28 1.75-in. OD Hydra-BlastTM Pro Tool October 2006

 Removing and Replacing Bearings
Use the bearing-replacement rotor-positioner tool (SAP No. 101246099) to remove
bearings. In the following procedures, this tool is referred to as the assembly tool (Figure
48). Only replace bearings if necessary, and take extra caution because the bearings can
be damaged during removal or installation.

Figure 48—Bearing-replacement/rotor-positioner tool

Transmission Housing
To remove bearings from the transmission housing and replace them, perform the follow-
ing steps:

1. With the transmission housing in the vise, insert the assembly tool or a brass rod
(0.755- to 0.90-in. OD) into the housing from the bottom.

2. Tap the bearing out of the housing (Figures 49 and 50).

3. Insert the bearing into the top of the transmission housing, making sure to align it into
the groove that will trap it.

4. Using the assembly tool or a brass rod, tap the bearing into place (until it is flush with
the top of the groove). Be careful not to damage the bearing during this procedure.

Figure 49 Figure 50

October 2006 1.75-in. OD Hydra-BlastTM Pro Tool 29

 External Torque Transmitter Gear and Ring Gear
To assemble the external torque transmitter gear to the ring gear perform the following
steps:

Note To reduce friction, use oil on the teeth, inside the ring gear, and outside the transmitter.

1. Rotate the two gears and find where the teeth of the gears want to mate (Figure 51).
The fit may be a press fit, but ensure that the gears have started mating before pro-
ceeding to the next step.

2. Using a flat surface, gently tap the two gears together until the end of the torque
transmitter gear is flush with the end of the ring gear (Figures 52 and 53). Ensure that
the teeth are mating correctly when performing this step.

These gears are now one piece. When disassembling the gear section, you will not
have to separate these pieces if they are a tight fit.

3. Remove the bearings from the torque transmitter gear and replace them. Insert the
bearings into both ends of the gear, making sure to align the bearings in the groove
that will trap them.

Note The bearings will slide in and out of the grooves with little resistance (Figure 54).

Figure 51 Figure 52

Figure 53 Figure 54

30 1.75-in. OD Hydra-BlastTM Pro Tool October 2006

 Top Driveshaft Extension
To remove bearings from the top driveshaft extension and replace them, perform the
following steps:

Note The bearing should slide in and out of the groove with little resistance.

1. Insert the assembly tool or a brass rod (0.54-in. OD) into the bottom of the gear, and
tap the bearing out if the bearing is trapped in the groove (Figure 55).

2. Insert the bearing into the top of the follower gear, making sure to align the bearing
into the groove that will trap it.

3. Using the assembly tool or a brass rod, tap the bearing into place (until it is flush with
the top of the groove) if the bearing does not slide in easily. Be careful not to damage
the bearing during this procedure.

4. Slide the bearing over the threads on the top driveshaft extension. The bearing should
slide over the threads with little resistance. Be careful not to damage threads or the
bearing during this procedure (Figure 56).

Figure 55 Figure 56

October 2006 1.75-in. OD Hydra-BlastTM Pro Tool 31

 Bottom Cap
To remove bearings from the bottom cap and replace them, perform the following steps:

1. Insert the assembly tool or a brass rod (0.755-in. OD) into the bottom end of the cap,
and tap out the bearing (Figure 57).

2. Insert the new bearing into the top of the bottom cap, making sure to align it in the
groove that will trap it.

3. Using the assembly tool or a brass rod, tap the bearing into place until it is flush with the
top of the groove (Figure 58). Be careful not to damage the bearing during this procedure.

Figure 57 Figure 58

Assembling the Hydra-Blast™ Pro Tool

This section explains how to properly redress the Hydra-Blast™ Pro tool assembly with
the bearing-replacement rotor-positioner tool (SAP No. 101246099), also called the
assembly assistance tool. When the tool is used, the rotor is held in the proper position,
eliminating the measurement requirements in the following instructions.

Caution The assembly assistance tool should be used only for assembly and oil filling. Re-
move tool after filling with oil. Never run the Hydra-Blast™ Pro tool with the
assistance tool installed.

Note: Use Loctite® 242 sealant (50 ml) SAP No. 100029228 for temperatures up to 300°F or
Loctite® 272 sealant (50 ml) SAP No. 100137732 for temperatures above 300°F on
threads. Apply Loctite® 242 sealant or 272 sealant (minimum 360° coverage on the first
thread) during makeup of the tool to threaded connections that could potentially experi-
ence torque during a job.

32 1.75-in. OD Hydra-BlastTM Pro Tool October 2006

 1. Place the top sub in the vice gripping on the flats of the top sub.

2. Insert the assembly assistance tool into the top sub (Figure 59).

3. Make up the stator onto the top sub (Figure 60).

Note Both ends of the stator are identical.

Figure 59 Figure 60

4. Make up the double joint to the rotor (Figure 61).

5. Make up the flow adapter to the double joint (Figure 62).

Figure 61 Figure 62

October 2006 1.75-in. OD Hydra-BlastTM Pro Tool 33

 6. Push the rotor, the double joint, and the flow adapter into the stator, making sure to
rotate the rotor while you push it in (Figures 63 and 64). The top of the rotor will
contact the assembly tool in the top sub, positioning the rotor correctly.

Important Use grease on the rotor only if the tool is to be used immediately, otherwise, use
nonhydrocarbon lubricant if necessary.

Figure 63 Figure 64

7. If the assembly tool is not available, push the rotor into the stator until the first joint of
the double joint extrudes from the stator approximately 1 in. (Figure 65). The top of
the rotor should be approximately 9.5 in. from the top sub (Figure 66). Measurement
is only required if you are not using the installation tool.

Figure 65 Figure 66

34 1.75-in. OD Hydra-BlastTM Pro Tool October 2006

 8. Generously apply a high-temperature grease to the double joint to protect its moving
parts from rust or corrosion (Figure 67).

9. Screw the camshaft onto the flow adapter. Use the wrench-flats on the camshaft to
tighten (Figure 68).

10. Grease the ID of the double joint extension housing where the piston will seal
(Figure 69).

11. Install the O-rings and PolyPak seal onto the piston. Mark the direction of the piston
so that the lip of the PolyPak seal is facing downhole (Figure 70).

Figure 67 Figure 68

Figure 69 Figure 70

October 2006 1.75-in. OD Hydra-BlastTM Pro Tool 35

 12. Grease the ID of the double joint extension housing and drive the piston into the
double joint extension housing to a length of 5 1/2-in. from the end. Mark the double
joint extension to match the direction of the Polypak seal (Figures 71 and 72).

Figure 71 Figure 72

13. Slide the double joint housing over the piston and camshaft and screw the double joint
extension housing onto the stator (Figure 73).

14. Install the threaded bushing and thrust washer onto the camshaft. Tighten the threaded
bushing using a wrench on the bushing and on the camshaft. Do not over-torque the
threaded bushing (Figure 74).

Figure 73 Figure 74

15. Ensure that the bearing in the transmission housing is in place (refer to the bearing
assembly instructions on Page 29).

36 1.75-in. OD Hydra-BlastTM Pro Tool October 2006

 16. Slide the transmission housing over the camshaft and thread it onto the double-joint
extension housing (Figure 75). If the assembly tool is not used, some resistance
should be expected since the rotor is being forced 0.5 to 1 in. into the stator.
• If the top of the rotor is approximately 8.4 in. from the top of the sub (Figure 76),
proceed to Step 18.

• If the top of the rotor is less than 8.25 in. from the top of the sub, the rotor has been
inserted too far into the stator. Insert a brass bar through the top sub and onto the
top of the rotor. Tap the rotor down slightly, making sure not to damage the rotor.

Figure 75 Figure 76

17. With all of the bearings properly placed within the gear sections (Refer to “Removing
and Replacing Bearings” on Page 29), assemble the sections so they form a single
assembly (Figures 77 and 78). Do not put the Polypak seal in the top driveshaft
extension at this time.

Figure 77 Figure 78

October 2006 1.75-in. OD Hydra-BlastTM Pro Tool 37

 18. Slide the assembly into the bottom of the transmission housing and onto the camshaft
until the two lugs on the stationary drive gear slide into the mating lugs in the trans-
mission housing. Rotate the gear section while sliding it into the housing to ensure
that it mates the lugs and aligns the gears onto the camshaft (Figure 79).

Note If mated properly, the camshaft should extrude approximately 3/16 to 1/2-in. from the gear
section (Figure 80). If it extrudes less than 1/4-in., the lugs on the stationary gear are
improperly mated inside the transmission housing. Rotate the gears while pushing them
forward until they mate.

Figure 79 Figure 80

Note You can use the output driveshaft to help rotate the gears while pushing them up to mate
with the lugs.

Caution Failure to perform Steps 19 through 23 correctly can result in seal damage.

19. Place the Polypak seal on the camshaft (with the O-ring facing the top of the tool),
and carefully work the seal into the recess of the top driveshaft extension (Figures
81 and 82). This arrangement helps prevent seal damage.

Figure 81 Figure 82

38 1.75-in. OD Hydra-BlastTM Pro Tool October 2006

 20. Ensure that the seal is captured inside the top driveshaft extension (Figures 83 and
84).

Figure 83 Figure 84

Caution Do not pull the output driveshaft off the camshaft after performing Step 21. The
Polypak seal will pull off, forcing you to repeat Steps 19 through 21.

21. Install the bearing over the top driveshaft extension.

22. Screw the output driveshaft onto the top driveshaft extension, and hand-tighten it.

Caution Do not apply excessive torque through the gear section (Figures 85 and 86). The
output driveshaft and the top driveshaft will tighten when the tool is operated.

Figure 85 Figure 86

October 2006 1.75-in. OD Hydra-BlastTM Pro Tool 39

 23. Slide a thrust washer, the bearing, and a second thrust washer onto the output
driveshaft (Figure 87), making sure that the last washer is flush with the end of the
transmission housing when the washer is in place on the driveshaft (Figure 88).

Figure 87 Figure 88

24. Insert the Parker seal into the proper groove in the bottom cap, making sure to install
the seal with the cup face facing downward. The solid face should be facing the
uphole position.

25. Install the wiper seal into the bottom cap. This wiper seal keeps debris away from the
Parker seal. Place the wiper seal in the bottom groove with the wiper lip facing down
(Figures 89 and 90).

Proper wiper seal installation

Figure 89 Figure 90

40 1.75-in. OD Hydra-BlastTM Pro Tool October 2006

 26. Make up the bottom cap (left-hand threads) into the transmission housing, making
sure to prevent the output driveshaft from rotating. The bottom cap should completely
enter the transmission housing with little resistance (Figure 91).

Figure 91

27. Make up the clutch assembly onto the output driveshaft (Figures 92 and 93).

Figure 92 Figure 93

28. Attach the appropriate cleaning head, cutting head, or blank head to protect the
threads.

October 2006 1.75-in. OD Hydra-BlastTM Pro Tool 41

Oil Filling Instructions
Follow these instructions for filling the oil section with oil. Use the assembly tool in the
top sub to prevent rotor movement during this process. If the assembly tool is not avail-
able, be sure to hold the rotor at the proper measurements (Step 2). If the lubricants listed
here are not available, use a high-quality synthetic oil.

1. Ensure that the assembly tool (Part No. 101246099) is in place. The assembly tool
will prevent the rotor from being pumped uphole when the oil is pumped into the tool.

2. Ensure that the distance from the top sub to the top of the rotor is approximately
8.5-in. (Figure 94).

Figure 94

Important The distance from the top sub to the top of the rotor must be approximately 8.5-in. when
you fill the transmission with oil. (Measurement is only required if you are not using the
installation tool.)

3. Remove the nozzle from the end of the tool to allow visual inspection to ensure the
Polypak seal is installed properly.

4. Attach the Martin-Decker hand pump to the 1/8-in. NPT threaded port on the transmis-
sion housing (Figure 95).

5. Fill the hand-pump reservoir with the appropriate oil, and pump the oil until the oil
section of the tool is full and oil exits the 1/8-in. NPT port on the bottom sub (Figure
96).

42 1.75-in. OD Hydra-BlastTM Pro Tool October 2006

Figure 95 Figure 96

6. Attach the 1/8-in. NPT pipe plug to the bottom sub.

Important During Step 7, the rotor must be held down by the assembly tool. Otherwise, the
internal parts of the transmission section can be pushed upward, pulling the PolyPak
seal from the camshaft. If you are not using the assembly tool, keep the rotor at 8.5-in.
from the top sub.

7. Stroke the pump a few times until sufficient pressure builds within the housing, forcing
oil around the bearings and pushing the piston to the upper position (Figure 97).

Important Make sure the rotor does not move.

Figure 97

8. Hold minimal pressure on the transmission section for 1 minute, and allow the piston
to move up.

9. Slowly remove the pump from the transmission housing, releasing any pressure
buildup.

October 2006 1.75-in. OD Hydra-BlastTM Pro Tool 43

 10. Insert the 1/8-in. NPT pipe plug into the port, trapping the oil in the transmission
housing.

11. Ensure that oil does not exit the ID of the output driveshaft. An oil leak could indicate
a defective Polypak seal.

12. Remove the top sub from the stator and pull the assembly tool from the top sub.

Note The assembly tool can be stored in the top sub, but it must be removed before operating
the tool.

13. Attach the top sub to the stator and install a thread protector in the top sub.

14. Reattach the nozzle (Figure 98).

Figure 98

15. A good Best Practice is to mark the tool with the address, date, stator temperature
rating and joints where Loctite® sealant is applied (Figure 99).

Figure 99

44 1.75-in. OD Hydra-BlastTM Pro Tool October 2006

Cutting Tubing with the Hydra-Blast™ Pro Tool
Although the Hydra-Blast™ Pro tool was designed to replace the Hydra-Blast™ indexing
tool and is used primarily for scale removal, it can also be used for cutting tubing. Figures
100 and 101 show the Hydra-Blast™ Pro tool configured with a cutting head inside a 4-
in. OD, 2.25-in. ID spiral drill collar. These photographs were taken immediately after a
cutting test in the yard. The drill collar was completely cut in 10 minutes. Notice that one-
half of the collar is smoothly cut, while the other is roughly cut. Although the cut surface
is rough, the OD and ID of the collar are free of burrs or flares that may cause an overshot
to become stuck during fishing operations. This test used a 1.80-in. OD cutting head with
two 0.093-in. carbide nozzles.

Figure 100 Figure 101

Figure 102 shows cut 3 1/2-in. tubing with an electrical, submersible pump cable strapped
beside it. The customer wanted to cut both the tubing and the cable at the same point in
the well. Other cutting methods, such as explosive or chemical cutting, could not ensure a
complete cut of the cable.

Figure 102

October 2006 1.75-in. OD Hydra-BlastTM Pro Tool 45

 Job Information
Before designing a cutting job with the Hydra-Blast™ Pro tool, obtain the following
information:

• Minimum restriction in the wellbore

• OD and ID of the tubing or drillpipe to be cut

Note As a general guideline, tubing thicknesses over ½-in. will have a decreasing likelihood of
success if all recommended procedures are not strictly adhered to.

• Grade of steel to be cut

• Depth at which the cut will be performed

• Bottomhole pressure and temperature

• Well circulation capabilities (determine whether circulation can be established)

• Maximum allowable pull on the tubing being cut

• CT size and length

• CT unit pressure rating

Equipment
CT Unit
A CT unit with a minimum pressure rating of 5,000 psi is appropriate. The pressure drop
across the cutting nozzles should be at least 3,000 psi, preferably 3,500 psi.

Pumping Unit
The pump should be capable of pumping 5,000 psi at a steady flow rate, and the user
should be capable of recording flow rate and pressure. The Halliburton RCM® mixing
system is ideal for this application. It can mix and hold the gelled fluid. It can also premix
the sand during circulation, allowing the sand to be maintained in suspension.

Holding Tank for Gelled Fluid and Blender

If a Halliburton RCM® mixing system is not used, identify another method of mixing and
holding the gelled fluid. 1,500 gal of a good 30-lb gel is recommended for cutting proce-
dures. The holding tank should be clean, and the fluid should be filtered before the gel is
mixed.

46 1.75-in. OD Hydra-BlastTM Pro Tool October 2006

 Gelled Fluid
A gelling agent capable of creating a 30-lb gel is appropriate. The gel type is determined
by well conditions, including bottomhole temperatures and well fluids. Consult with an
area field engineer before designing a gel for cutting tubing.

Cutting Material
The recommended cutting material is 100-mesh (50 lb/sack P/N 101213353) sand mixed
at a maximum concentration of 0.50 lb/gal. The best results have been achieved with
sand concentrations of 0.30 to 0.50 lb/gal pumped at a minimum rate of 1/2 bbl/min but
recommended between 30 and 35 gal/min with a pressure drop across the nozzles of
approximately 3,500 psi.

Note Using a lower mesh sand will result in more severe tool erosion and is discouraged.

Laptop Software/Spreadsheet Cutting Job Design

The recommended nozzle size, quantity, and corresponding flowrate to attain the targeted
3,500 psi pressure drop are listed in Table 12. If possible, contact the CT Tools Global
Advisor with all the necessary job details to accurately predict the expected surface
pressure for your job. Outrite will no longer be used for this calculation; a newly devel-
oped CT Friction Pressure spreadsheet is to be used. The spreadsheet is available at this
location: http://halworld.corp.halliburton.com/internal/PS/pe/contents/Procedures_and_
Manuals/web/CTHydraulics.xls. The spreadsheet is for internal use only, the security
password is pluto.

Table 12—Recommended Cutting Job Parameters

Nozzle Size Nozzles Flowrate Pressure Drop
(in.) (qty) (gal/min) (psi)
0.078 3 23 3,500
0.089 3 30* 3,500
0.093 3 33* 3,500
* Within optimum flowrate range (30-35 gal/min)

October 2006 1.75-in. OD Hydra-BlastTM Pro Tool 47

 The nozzle size, quantity, and flowrate are entered into this spreadsheet to yield the
3,500 psi pressure drop across the nozzles. Kp and n values are entered from Fann®
Instrument Data or the Material Library as well as Coiled Tubing string data to predict the
surface pressure for the Hydra-Blast™ tool cutting job. A sample calculation is included
in Appendix D, page 56.

Note These figures assume a new nozzle (i.e.: discharge coeff (Cd) = 0.75).

CT Friction Pressure
Prepared by Robert G. Howard
Generated Wednesday, September 20, 2006
CT Geometry
OD (in.): 1.5 Total Length (ft): 8000
Wall Thickness (in.): 0.156 Length in Well (ft): 6000
Tapering: (see the CT Profile) Roughness (in.): 0.0018
Reel Parameter
Reel Diameter (in.): 72
Casing
ID (in.): 3.958
Fluid Properties
Name: 35# Guar Density (ppg): 8.33
Type: Newtonian Non-Newtonian Viscosity (cP)

n:
Input n and Kp
Kp (lbf-sn/ft2):

n: 0.462
From Fann Data
Kp (lbf-sn/ft2): 0.01503
Other Input
Bit Discharge Coefficient: 0.95
Nozzle 1, in.: 0.3125
Nozzle 2, in.: 0.3125
Nozzle 3, in.: 0.3125
Nozzle 4, in.: 0.3125
Total DP of Motor (psi): 1100

Flow Rate (BPM): 3

Summary of Calculation Results

DP in straight sect. of CT (psi): 2281.0 ECD (ppg): 8.78
DP in coiled sect. of CT (psi): 1609.7 TFA (sq. in.) 0.31
Total DP in CT (psi): 3890.7 Total impact force (lbf): 71.64
DP in annulus (psi): 140.5
Total DP in CT & annulus (psi): 4031.2
Total DP of motor (psi): 1100.0
DP in bits (psi): 129.4
Total DP (psi): 5260.6
HHP required: 386.7
Fann Data (#1 Spring)
RPM Dial Reading
600 32
300 23
200 19
100 14
6 3
3 2 .

Figure 103—Example of CT Friction Pressure spreadsheet

48 1.75-in. OD Hydra-BlastTM Pro Tool October 2006

 Downhole Tools
Table 13 lists recommended downhole tools for cutting jobs. Table 13 does not provide
part numbers for the CT connector, cutting head, carbide nozzles or a mechanical hold-
down. Information about these downhole tools follows
• CT Connector. Refer to Section 2 of the Coiled Tubing Tools Manual (Part No.
H00949, SAP No. 101335389) to determine the appropriate connector. If pos-
sible, use a 1.315-in. OD, 2.25-lb OECO “A” pin thread.
• Cutting Head. Because the cutting head is designed to fit particular tubing sizes,
it is custom-built at the local level. Appendix B provides guidelines for machin-
ing a cutting head locally.
• Carbide Nozzles. Carbide nozzles have 1/4-in. NPT threads. Table 14 lists
carbide nozzles and SAP part numbers.
• Hold-down. The use of a “stop” hydraulic hold-down or other anchoring means
is imperative to ensure the cutting plane remains constant (Figure 104, Page 50).
Pump rate variations, differing fluid densities or hydrostatic pressure changes can
cause minor downhole tool movement (several inches), which in turn results in a
new cut being started. Even a one inch shift will result in a fresh cut depth.

Table 13—Recommended Bottomhole Assembly for Cutting Jobs

SAP Part No. Description Connection
100070716 1.75-in. OD double-flapper check valve 1.315-in. OD 2.25-lb/ft OECO "A" box x pin
100004086 1.81-in. OD hydraulic disconnect 1.315-in. OD 2.25-lb/ft OECO "A" box x pin
100070798 1.75-in. OD ball-drop circulating valve 1.315-in. OD 2.25-lb/ft OECO "A" box x pin
100070842 1.81-in. OD rupture disc sub 1.315-in. OD 2.25-lb/ft OECO "A" box x pin
100071267 1.75-in. OD H-B Pro tool 1.315-in. OD 2.25-lb/ft OECO "A" box x pin
101317673 1.75-in. OD motorhead 1.25-in. OD CT connector x 1.00-in. AMMT pin
101353530 1.75-in. OD motorhead 1.00-in. AMMT box x pin

Table 14—Carbide Cutting Nozzles

SAP Part No. Description
101241675 0.093-in. Nozzle tip
101241676 0.089-in. Nozzle tip
101241677 0.078-in. Nozzle tip

October 2006 1.75-in. OD Hydra-BlastTM Pro Tool 49

 If well configuration allows use of a “Stop”
to help keep the tool stationary during cutting

Place tension on the pipe to be cut

Slow rotating Hydra-Blast™ Pro tool

with cutting nozzle

Pipe has been cut

Figure 104—Cutting casing using a “Stop”

Prejob Procedures
If possible, conduct a yard test on the tubing/casing/drillpipe to be cut with the equipment
that will be used for the cutting job. Expect downhole conditions to at least double the
cutting time during the actual job. For example, if the cutting time during the yard test is
10 minutes, design the actual procedure with enough fluid and sand for a minimum of 20
minutes pumping time. If you cannot perform a yard test, design the cutting job with
1,500 gallons of fluid and 500 to 750 lb of sand.

50 1.75-in. OD Hydra-BlastTM Pro Tool October 2006

 Recommended Job Procedures

To perform a cutting job with the Hydra-Blast™ Pro tool, follow these steps:

1. Place tension on the tubing to be cut by pulling on it, and set the tubing on slips
before connecting the CT wellhead equipment. The recommended minimum tension is
10,000 to 20,000 lb/ft over string weight.

Note Overpull helps the cutting job and may indicate when the tubing is completely cut.

2. Circulate the CT with clean fluid and over-displace several barrels before attaching it
to the Hydra-Blast™ Pro tool to remove most of the debris and scale.

3. Connect the Hydra-Blast™ Pro tool to the CT, and pump fluid through the tool to
verify proper rotation and determine pump pressures and flowrates.

4. Connect the CT injector to the wellhead.

Caution Do not set weight on the tool’s cutting head. The cutting head can be damaged.

5. Begin running the CT in the hole slowly until the tool has passed all surface equip-
ment and entered the tubing or casing. Move the tubing past restrictions very slowly.

6. Premix the gel (do not add sand at this time) before the Hydra-Blast™ Pro tool reaches
the cutting depth. A 30-lb gel will normally be sufficient for carrying the sand and
reducing the friction in the CT.

7. Do not move the CT after the cutting depth is reached.

8. Pump a small volume of spacer (clean gel) between the well fluid and the sand slurry.

9. Add the sand to the gel on-the-fly, or premix in an RCM® mixer. If you mix on-the-
fly, maintain a constant sand concentration and avoid creating sand slugs. Mix the
sand at a concentration of 0.30 to 0.50 lb/gal.

10. Pump slowly until the sand slurry nears the Hydra-Blast™ Pro tool. This will help
prevent tool wear and help ensure that the nozzles are not cut.

11. Bring pump rates and pressures up to the recommended levels predicted by the
software. Stress to the pump operator the necessity of maintaining a constant flowrate
throughout the cutting job to keep the pressure drop across the nozzles in the required
range.

Caution Limit the maximum flow rate for cutting jobs to 35 gal/min. Severe Hydra-Blast™
Pro tool erosion can occur at higher flow rates.

October 2006 1.75-in. OD Hydra-BlastTM Pro Tool 51

 12. Monitor returns from the tubing being cut and from its backside. Changes in returns
are a good indication that the cutting job is almost complete.

13. If possible, monitor the tension in the tubing. A release in tension indicates that the
tubing is free.
• If return changes indicate a complete cut, reduce the pump rate to prevent the
outside casing from being cut. Decrease the pressure across the nozzles to below
500 psi to help prevent casing damage.
• If returns do not change, and a cut is not indicated, continue pumping until all the
gel/sand mixture has cleared the CT and come up the backside of the tubing being
cut about 1,000 ft.

14. Slowly remove the CT while continuing to circulate fluid.

Caution Do not overrun the returns (remove CT faster than the travel rate of the fluid being
circulated) on the trip out. Otherwise, sand can be left in the well.

Job Completion Procedures

After the tubing has been completely cut, perform the following steps:

1. Remove the CT from the wellhead.

2. Pump fluid through the Hydra-Blast™ Pro tool to ensure proper rotation.

3. Flush the tool with fresh water.

4. Redress the tool and inspect individual parts for damage.

5. The rig/workover unit can move the well tubing to ensure that it is free at this time.

6. If the tubing is not free, repeat the cutting procedures. If possible, perform the second
cut at a shallower depth in case the tubing is stuck at a depth above the first cut.

52 1.75-in. OD Hydra-BlastTM Pro Tool October 2006

Appendix A—Cleaning-Head Examples
Figure 105 shows a 1.75-in. OD blank cleaning head. If you do not have time to purchase
a new head from the Duncan warehouse before the job, use this drawing at a local ma-
chine shop to build a head. This drawing is applicable for cleaning heads up to 2-in. in
diameter, but the ID should be modified to maintain a wall thickness of 0.25 to 0.375 in.
Machine the head from 4130 or 4140 steel heat-treated to Rc 22 minimum.

4.0
Mill 6 flats- 0.04 deep-
1.2 60º apart
30º
45º 30º

±0.03 ±0.02
1.50 1.28 1.14
1.17
1.28 0.5
1.75 Drill
Permissible

0.12
0.20
11/4 in - 12UNF - 2B
±0.03
BD - 1.160-1.178 1.04
PD - 1.1959-1.2034 ±0.02
3.38

Figure 105—1.75-in. OD cleaning-head blank

Figure 106 (Page 54) shows a 2.16-in. OD blank cleaning head. Notice that the upper thread
(1 3/4-in. - 12 UN) is larger than the blank heads under 2.00-in. diameter. Remember that the
OD and ID of the head should be sized to ensure the proper wall thickness. See Detail B in
Figure 107 for minimum and maximum wall-thickness values.
Figure 107 (Page 54) shows the proper jet placement for jet cleaning operations. The
Hydra-Blast™ software determines necessary jet quantity. The program assumes that four
jets will be placed on the bottom of the cleaning head as down blasts and that the remain-
ing jets will be spaced equally at 0.25-in. intervals in three vertical rows on the side of the
cleaning head.

Note The maximum and minimum wall thickness should be between 0.38 and 0.25-in. (as shown
in Detail B).

October 2006 1.75-in. OD Hydra-BlastTM Pro Tool 53

 ±0.03
5.44

1.5
Mill 6 flats- 0.04 13/4-12UN-2B
deep - 60º apart BD 1.660-1.678
PD 1.6959-1.7036
30º 45º

30º

+0.00
-0.02
1.78 1.78 2.16
2.0 0.5
±0.03 1.34
1.66 Drill
permissible

0.12 0.2
±0.03
1.83
±0.02
4.54

Figure 106—2.16-in. OD cleaning-head blank

Dia. determined Ø.059

according to
Hydra-Blast
program. Ø.188
(0.094)

Min. of 0.25
Max of 0.38
Leave sharp
edge
Detail B

11/4-12UNF 3 equal rows 1.50

A or 13/4-12 UN 0.25
120º apart
TYP 3 places
according to
120º apart
head OD

See detail B
TYP

A Section A-A

Figure 107—Proper jet placement and design

54 1.75-in. OD Hydra-BlastTM Pro Tool October 2006

Appendix B—Cutting-Head Examples
Cutting heads are not available from the Duncan warehouse. Because several cutting-head
variations can be used with various sizes of tubing and casing, cutting heads should be
manufactured locally according to Figure 108.
Cutting nozzles are available from the Duncan warehouse. See Table 14 (Page 49) for
SAP numbers. Contact Duncan Tool Systems Engineering for help designing a cutting
head (580-251-2184 or 580-251-3271).

5.00 3 × drill Ø 7/16 (.4375)

4.25 1/ NPT thread
4
3.25 2 rounds past flush
2.00 120º apart
1.04 (0.50)
0.12 0.20
Drill
Ø0.50
permissible
45º

(Ø 1.75) Ø1.17
(Ø 3.00) Ø1.50 Ø1.25 Ø.50 Ø1.20
OD Ref Ø1.25

45º
11/4 - 12 UNF - 2B 30º
Mill 4 flats .04
BD - 1.150 - 1.17B
90º apart
PD - 1.1859 - 1.2034

Figure 108—Cutting-head design

Guidelines for Designing Cutting Heads

• The OD of the cutting head depends on the ID of the tubing to be cut. The OD of the
cutting head should be 1 to 2-in. smaller than the ID of the tubing. For example, 2.99-in.
tubing would require a cutting head with a 1.75- to 2-in. OD. The smallest cutting head
available would be 1.75-in. because the OD of the Hydra-Blast™ Pro tool is 1.75-in.

• Each cutting head should be designed with three 1/4-in. NPT ports arranged 120° apart.
This design helps keep the tool centralized within the tubing.

• Use nozzles that provide a pressure drop of 3,500 psi at a pump rate of 30 to
35 gal/min. The 0.089-in. nozzles work well.

• Use an ID of 0.5-in. for the cutting head, and allow enough wall thickness to hold the
cutting nozzle.

October 2006 1.75-in. OD Hydra-BlastTM Pro Tool 55

Appendix C—Spare Parts Lists
Two spare parts kits are available for the Hydra-Blast™ Pro tool. One kit contains the
seals and O-rings necessary for redressing the tool after each job (Table 15). The other kit
contains the bearings for the tool and the spare parts for the double universal joint (Table
16).

Table 15—Seal Redress Kit (SAP No. 101206467)

SAP
Description Qty.
Part No.
101208960 Polypak seal - 0.75-in. OD × 0.50-in. ID × 0.125-in. width 5
101208957 Polypak seal - 1.125-in. OD × 0.875-in. ID × 0.125-in. width 5
101214817 Rotary seal - 1.08-in. OD x .750-in. ID x .183 radial x .215 axial 5
100026671 O-ring, 70 duro - 1 1/8-in. OD x 1-in. ID x 1/16-in. width 5
100026753 O-ring, 90 duro - 1 7/16 OD x 1 5/16-in. ID x 1/16-in. width 20
100001935 O-ring, 90 duro - 1 1/4-in. OD x 1 1/16-in. ID x 3/32-in. width 10
100012947 O-ring, 90 duro - 1-in. OD x 3/4-in. ID x 1/8-in. width 2
100040533 200 Single wall container, 3 5/8-in. x 3 5/8-in. x 3 5/8 ID 1
101241917 Slotted heal wiper seal, 1.125-in. OD × 0.75-in. ID × 0.187-in. base 5

Note This kit contains enough parts to rebuild the 1.75-in. Hydra-Blast™ Pro tool, SAP No.
100071267 (698.25200), or SAP No. 101208071 (698.25202) five times.

Table 16—Bearing Redress Kit (SAP No. 101216034)

SAP Quantity
Bearing Description (in.)
Part No. in Kit
101246101 Sleeve bearing, 0.75-in. OD × 0.625-in. ID × 0.50-in. long 2
101246102 Sleeve bearing, 0.812-in. OD × 0.75-in. ID × 0.50-in. long 1
101246103 Sleeve bearing, 1.00-in. OD × 0.75-in. ID × × 0.75-in. long 2
101246104 Sleeve bearing, 1.25-in. OD × 1.00-in. ID × 1.00-in. long 1
100071288 Thrust washer, 1.250-in. OD x 0.750-in. ID x 0.0935-in. width 4
101246105 Thrust bearing, 1.25-in. OD × 0.75-in. ID × 0.078-in. thick 3
101246100 Sleeve bearing, 0.687-in. OD x 0.50-in. ID × 0.75-in. long 1
100040565 Taped 200 container, 2 5/8-in. x 2 5/8-in. x 3 1
101228588 Large pin - knuckle joint 2
101228596 Small pin - knuckle joint 2
101228602 Lock ring - knuckle joint 2
101354890 Screw-on camshaft bushing, 1.75-in. OD 1

Note This kit contains parts to replace all bearings in the 1.75-in. Hydra-Blast™ Pro Tool, SAP
No. 100071267 (698.25200), or SAP No. 101208071 (698.25202) one time. Use bearing
removal and replacement tool, SAP No. 101246099.

56 1.75-in. OD Hydra-BlastTM Pro Tool October 2006

Appendix D – Hydra-Blast™ Tool Cutting Sample Calcula-
tion
Table 17 lists three different nozzle configurations that will generate the required 3,500-
psi pressure drop. Of these three, only the last two fall within the recommeneded flowrate
range for proper motor motion.
The first step in utiling the new CT Friction Pressure spreadsheet is to enter chosen
nozzle size, nozzle quantity, flowrate, discharge coefficient, and pressure drop through
the Hydra-Blast™ tool (500 to 1,000 psi) in the Other Input section. Enter fluid density
(approximately 9 ppg including sand) into the Fluid Properties section. Select the
Calculate button after entering these parameters to update Summary of Calculation
Results numbers. Confirm the DP in Bits (pressure drop through nozzles) is approxi-
mately 3,500 psi as Table 17 predicts.
The second stage in the process of predicting cutting job surface pressure involves
inputting the coil string geometry (Coiled Tubing diameter, length, tapered sections, reel
diameter, etc..) as well as casing size and the remaining fluid properties. Fann® Instru-
ment Data or direct inputs from the materials library may be entered in the remaining
Fluid Properties section before selecting the Calculate button again. Prediction of
surface pressure (Total DP psi) is given under Summary of Calculation Results.
The results of these steps will give the critical flowrate for the needed 3,500-psi pressure
drop based on the nozzle configuration chosen.

Table 17—Pressure Drop Through 1.75-in. SRHB

Cutting Head Nozzles
Nozzle Size Nozzles Flowrate Pressure Drop
(in.) (qty) (gal/min) (psi)
0.078 3 23 3,500
0.089 3 30* 3,500
0.093 3 33* 3,500
* Within optimum flowrate range (30-35 gal/min)

October 2006 1.75-in. OD Hydra-BlastTM Pro Tool 57

Appendix E – “Cutting Tubing with the Hydra-Blast™ Pro
Tool”
(November 2002 internal Halliburton paper by Diego Londono)
One of the first field locations to cut pipe with the Slow Rotating Hydra-Blast™ Tool
was in Macae, Columbia. By November 2002, 14 jobs had been performed in that
country resulting in a wealth of learning and experience that was shared in a very infor-
mative procedural paper by Diego Londono.
Although there is some redundancy between the section on “Cutting Tubing with the
Hydra-Blast™ Pro Tool” and Londono’s paper, it is well worth reading. Every ounce of
extra effort spent in ensuring that all control-able aspects of the job are optimized, will
pay off in a higher percentage of first-time successful cuts.
Major points of interest and emphasis have been italicized and underlined.

Note: This paper was written prior to the introduction of the CT Friction Pressure spread-
sheet. The body of this paper has been fully maintianed with changes/corrections or
additions inserted appropriately in [closed brackets].

58 1.75-in. OD Hydra-BlastTM Pro Tool October 2006

 Cutting Tubing with the Hydra-Blast™ Pro Tool
Additional field recommendation for cutting jobs
Colombia Submitted by:Diego Londono
20th Nov., 2002 H082201

Since November 2000 when the Hydra-Blast™ Pro Tool was used for the first time to cut
pipe on a real job in Colombia, a total of 14 jobs have been performed in our country.
Overall well conditions faced range from cutting 3 ½-in S grade Drill Pipe at 14,749 ft
depth in a vertical well to cut a 4 ½-in Liner at 3,882 ft depth in a highly deviated well
(78 degrees).
Although success ratio has been low (54%), those has been the first jobs performed, we
can guarantee that the tool has a pretty high success ratio if the conditions are right
during job design and execution. During job’s execution, we have experiment different
issues that had lead designers to change several specifications from original tool.
Beside best practices, procedures and inspections referred in the tool manual, that should
be taken into account, main factors affecting job execution that you should take into
account to increase your chances of success are the followings:

Hydraulic Calculations
Perform hydraulic calculations considering all variables that affect pressure drop across
nozzles: injection pressure, WHP, Coiled Tubing friction loss, Tool pressure lost, hydro-
static pressure in Coiled Tubing and hydrostatic pressure in annulus Coiled Tubing/
Tubing. Use Hydra-Blast™ software, Halwin Friction package and CERBERUS [re-
placed with new CT Friction Pressure spreadsheet] to calculate pressures and be sure
that pressure drop across nozzles is above 3,500 psi.

Variable Value, psi

Injection Pressure, + 6,000
WHP, - 300
Coiled Tubing Friction Loss, - 1,350
Tool Pressure Loss, - 1,000
Hydrostatic Pressure on CT, + 3,100
Hydrostatic Pressure on Annulus, - 2,900
Pressure drop across nozzles 3,550

If pressure drop across nozzles is not above 3,500 psi, try to find a fluid that has less
friction or, if available, use a shorter or larger Coiled Tubing string. If your hydrostatic
pressure on annulus is high, for instance high density OBM, recommend to the customer
to change wellbore fluid before the job and perform calculations to find the maximum
fluid density on annulus.

October 2006 1.75-in. OD Hydra-BlastTM Pro Tool 59

 Desist to execute the job if pressure drop across nozzles is not above 3,500 psi and none
of the variables can be optimized to get the right value or use an excess of 50% slurry if
pressure calculation are between 3,000 and 3,500 psi.

Coiled Tubing Friction

From the variables involved in the above hydraulic calculations, Coiled Tubing friction
loss has the worst impact on job success if it is not properly estimated. To do so, perform
lab test to find rheological properties of final slurry to be used; estimate n’ and K’ and
use [CT Friction Pressure spreadsheet] to find a more accurate friction pressure (do not
forget to include in the software, different wall thickness of string you will use to execute
the job).

Hydrostatic Pressure on Tubing/Casing Annulus

You should also take into account the hydrostatic pressure related to the fluid in the
Tubing/Casing annulus: once you have establish circulation by actually open any hole or
cut any portion of the Tubing, the heavier fluid on annulus Coiled Tubing/Tubing or
Tubing/Casing will now govern your hydrostatic pressure on annulus. If the fluid in the
Tubing/Casing annulus is heavier, it will reduce considerably your Pressure Drop Across
Nozzles, you can not guarantee that the cut is going to be 100% efficient.

Sieve Analysis of Cutting Material

Be sure that the sand you will be using has a uniform distribution. Do not use sand if its
sieve analysis results in less than 65-70% of 100-mesh grains. Perform sieve analysis of
the local sand generally use for other applications and, if necessary, request the right one
and have available in stock at least for two cutting jobs. To use the right sand is one of
the main and critical issues to get success while cutting.

Displacement Fluid
To displace the slurry with the cutting material, it is critical to use a fluid that minimizes
nozzle movement: during a 10,000 ft depth cutting job, a movement of just 1-in. in nozzle
depth means that the job will need to start over again to perform the cut successfully and
at that point there may not be enough slurry available.
Nozzle movement is primarily governed by buoyancy (related to fluid weight in Coiled
Tubing and fluid weight and fluid level in annulus) and friction pressure loss. In terms of
displacement fluid, we can handle fluid weight and friction pressure loss -we will talk
about fluid level in annulus later on. For short, our displacement fluid has to reduce the
chance of nozzle movement caused for these two facts.
To provide such characteristic, first, the displacement fluid has to have the same density
of the slurry (fluid + sand); and second, it has to have similar rheological properties. To
achieve first characteristic, use a base fluid with more brine concentration for displace-
ment. For instance, if you will use 4% KCl (8.54 ppg) as base fluid for the slurry, use
around 9% KCl (8.81 ppg) as base fluid to displace if you will use 0.5 ppg of sand – use
actual sand absolute volume to properly calculate the “Dirty Density” out of the “Clean
Density” as the Frac people used to do.

60 1.75-in. OD Hydra-BlastTM Pro Tool October 2006

 To achieve second characteristic, use the same gelling type and concentration in both
fluids: never displace with diesel, crude-oil or any other fluid that has very different
friction behavior.

Fluid Level
Annulus fluid level affects Coiled Tubing buoyancy and as it was mentioned before,
nozzle movement is primarily governed by buoyancy. In the best scenario the fluid level
is on surface, or at a point close to surface, and during job execution pumping rate is
enough to maintain wellbore full all the time.
If this is your situation, fill it before the job and choke it back through an adjustable
chock to a stabilized and low pressure (100-200 psi). Although, displacement of annulus
fluid with sand slurry can also affect buoyancy and consequently nozzle movement, the
choke pressure on annulus will reduce changing fluids effect while pumping treatment.

Note Care must be taken to not increase choke pressure: slurry may be forced into formation
and sand settling may occur at bottom. If sand settling is not an issue, feel free to choke
annulus back).

If fluid level is far away below surface, you will have to face a tough scenario: you can
not ensure that your buoyancy is going to be the same during job execution. You will
have to be very lucky if pumping rate equals the well reservoir’s capacity of taking fluids
in such way fluid level on annulus remains constant. As this is hard to determine, the best
you can expect is to finish the cutting job before the fluid level change affects nozzle
position considerably. It has been done but you and mainly your client should be aware
of this situation that will influence cut success before executing the job. [Consider
pumping job with well shutin if possible, this may increase annular pressure and decrease
delta P.]

Job Execution
During job executing with sand on nozzle, try to maintain pumping conditions as stable
as possible. Five barrels before sand hits nozzles, increase pumping rate to match design
pressure. Once you get stabilized conditions and unless any unexpected even occurred,
do not increase or decrease pumping rate trying to much a constant pressure: if you do
so, you will be moving nozzle at depth. Depending on many factors, 200-300 psi of
difference in injection pressure will move nozzle several inches up or down. Be sure
before the job that your pump’s engine does not change its rpm by itself, [lock engine
fans on].

Cutting Nozzles Size

Decision to use one of the three size of cutting nozzles recommended in the Tool manual:
0.093-in., 0.089-in. and 0.078-in., depends on string length and its consequent fluid
friction drop. Use smaller nozzles if there is high Coiled Tubing friction: to achieve
higher working pressures, you will not need higher rates, especially over 35 gal/min.

October 2006 1.75-in. OD Hydra-BlastTM Pro Tool 61

 Use a “Stop”
If wellbore configuration allows, for instance, if it has a crossover with a change in
tubing ID above and close to the cutting depth, you could use a kind of “stop” above the
tool. Once you run in hole, you can apply weight at depth over the “stop” that will not
pass through the ID restriction eliminating nozzle movement caused for buoyancy or
pressure. Special care must be taken to use the “stop” in live wells: in any case you have
to analyze its viability in terms of safe rig up and rig down procedures.

Centralization
Use a BHA centralizer if target depth is above 30º. That will help to achieve a more
constant standoff that consequently will help to get a clean cut.

Additional Things to Remember:

• Read and follow instructions in the Tools manual.

• Use a “last generation” tool, or, if not available, be sure to upgrade according to,
TTT-01-005, TTT-01-012, TTT-02-001, TTT-02-012, TTT-03-024, TTT-04-002, and
TTT-05-001 technology bulletins.

• Keep extra seal and bearing redress kits and main spare parts available on location.

• Design the cutting head according to the Tools manual instructions. Have an addi-
tional head with nozzles available if more that one job may be performed.

• Test the tool on the yard before the job with enough time to repair it if required.

• Use blue Loctite to attach the cutting head to the tool.

62 1.75-in. OD Hydra-BlastTM Pro Tool October 2006

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10
26 18 41 11
1 1 26 2 7 3 26 4 6 27 28 16 5 9 7 26 45 22 23 32 14 13 24 15 36 19 22 21 23 30 8 38 44 20 10 25
29 22 OB

D C B

Ø 1.75 OD

2X Ø.313 Ø .438 ID Ø .312 ID Ø .380 ID

Ø 1.315 OD Ø .84 ID 13
2.25# OECO "A" BOX

8.41
0

24.89

41.39

44.53

46.32
31.92

50.32
Left hand thread

42 6 15

Detail D Detail C Detail B

Tool, Bearing Replacement, Rotor Posititoner Scale 4 : 1 Scale 4 : 1 Scale 4 : 1
Installation Detail Installation Detail Installation Detail

1.75-in. Hydra-Blast™ Pro Tool (698.25200)

Parts List and Notes for 698.25200 OB

Notes: 7. Temperature limit is the nitrile rubber in the stator.
Find SAP No. Qty. Description Find SAP No. Qty. Description
1. Mark per SPEC 70.72. The following stators are available for listed temperature ratings:
0001 100071268 1 Top sub 0022 100071288 3 Thrust washer
2. Transmission section should be filled with one of the following recom-
mended lubricants before operating tool (ship without oil): P /N Ov ersized D im ens io n M ax. T em perature R ating 0002 100071270 1 Stator 0023 101246103 2 Sleeve bearing
100071270 - 698.25207 250°F 0003 100071272 1 Rotor 0024 101246101 2 Sleeve bearing
PACER DHT 475C MOBIL SHC 639 MOBIL SHC 636 .000-in.
MOBIL SHC 634 MOBIL SHC 632 101207062 - 698.25232 .020-in. 300°F
0004 100071273 1 Double joint 0025 100071225 1 Cleaning-head blank
101207063 - 698.25251 .030-in. 350°F
3. Threaded blank cleaning heads 0005 100071274 1 Extension housing 0026 100026753 4 O-ring
Head OD Head P/N Split Ring Nozzle Adapter 0006 101294664 1 Camshaft adapter 0027 100001935 2 O-ring
1.60 100071224 - 698.25052 9. Clutch slips with 50 ft-lb torque at 3,500 psi.
101345672 0007 100071276 1 Transmission housing 0028 101208957 1 Polypak seal
1.75 100071225 - 698.25053 "
10. Maximum recommended flow rate is 50 gpm. 0008 100071277 1 Bottom cap 0029 101208960 1 Polypak seal
1.90 101002418 - 698.25054 "
11. 6,000 psi is the maximum working pressure. 0009 101294376 1 Transmission camshaft 0030 101214817 1 Rotary seal
2.00 100071226 - 698.25055 "
0010 101289883 1 Output driveshaft 0031 101216034 1 Bearing redress kit
2.16 101002419 - 698.25150 101345739 12. Redress kits for one time redress:
2.30 101002420 - 698.25151 " Replace seals after each run in hole - replace bearings only as needed. 0011 101294906 1 Split ring nozzle clutch sub 0032 100066460 2 Pipe plug
Seals kit: P/N 101206467 (698.25201).
2.60 101002421 - 698.25152 " Bearing kit: P/N 101216034 0012 101345739 1 Split ring nozzle adapter 0035 100001372 1 Vinyl bag
2.75 101002422 - 698.25153 " 0013 101289878 1 Torque transmitter gear 0036 101289605 1 Top driveshaft extension
13. Pins in double knuckle need to be cleaned and inspected after each run in hole. Refer to
Note: 100071225 (698.25053), 101345672, and 101345739 are included maintenance manual (101241870) for removal. Replace pins if showing unusual wear or 0014 100071283 1 Stationary drive gear 0038 101345672 1 Cleaning nozzle adapter
in assembly. damage. Pins and lock ring (101228588, 101228596, and 101228602) are included in
4. Certification and traceability required per SPEC 70.72. bearing redress kit. 0015 101289600 1 Output drive gear 0039 100001947 2 O-ring
0016 100071285 1 Floating piston 0040 101206467 1 Seal redress kit
5. Print (Item 34) to be sealed in Item 35 and shipped with assembly. 14. Assembly and operating instructions manual part number is 101241870 (Find 43).
0017 101289876 1 Torque transmitter gear 0041 101241917 1 Wiper seal
6. Item 12, Item 31, Item 40, Item 42, and Item 43 to be shipped with 15. Use Rotor Positioner Tool (101246099) during assembling of tool.
0018 101246104 1 Sleeve bearing 0042 101246099 1 Bearing-replacement tool
assembly.
0019 101246100 1 Sleeve bearing 0043 101241870 1 Manual
0020 101346296 1 Split ring retainer bearing 0044 100026671 1 O-ring
0021 101246105 1 Thrust bearing 0045 101354890 1 Screw-on camshaft bushing

October 2006 1.75-in. OD Hydra-Blast Pro™ Tool 63

64 1.75-in. OD Hydra-Blast Pro™ Tool October 2006
 CNOOC‐OTIS

Recommended Hand Tools

and Special Equipment for Tool Maintenance

Description Qty. 描述

18‐in. Pipe wrench 2 18 寸管钳

5/8‐in. Open‐end wrench 1 5/8 寸开口扳手

Small, flat‐blade screwdriver 2 小的，一字螺丝刀

1/4‐in. Hex wrench 1 1/4 寸内六扳手

3/16‐in. Hex wrench 1 3/16 寸内六扳手

O‐ring 1 O圈

1/8‐in. Flat punch 1 1/8 寸 铳子

Adjustable pliers 1 老虎钳

Small hammer 1 小榔头

Adjustable 12‐ or 14‐in. wrench 1 12‐14 寸扳手

High‐temperature thread grease 1 耐高温丝扣油

Large flat‐blade screwdriver with square blade 1 大十字螺丝刀

Bearing replacement/rotor positioner tool 1 专用保养工具

Martin Decker hand pump 1 手压泵

Retaining ring pliers 1 链钳

Wood dowel rod 1 1/8‐in. OD × 24‐in. long 1 木棒 1 1/8 寸外径×24 寸长

Tape measure 1 卷尺

1/1

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