2026 9.6 TST-3 Rev K PDF

BJ SERVICES COMPANY, USA
Service Tools Technical Manual

Subject: 9.6 TST-3 Service Packer
Index No: 2026 Revision: K Date: 2 February 2009 Page 1 of 26
Approval: Approval Date:
TST-3 SERVICE PACKER - 9.63” 29.3-53.5 PPF

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

Integral Unloader and Fluid Bypass. The TST-3 is well suited to operations such as spotting fluids while the tool
is still set. The bypass design also allows circulation around the bottom of the tool, allowing rapid removal of
debris, cement or treating fluids from the bottom of the tool.
Reliable Packer Control. The TST-3 features an exposed J-slot control mechanism. This rugged packer control
system provides reliable function in all well conditions. The exposed J-slot allows debris to be flushed from the
control system insuring that the packer may be set and retrieved in even marginal well conditions.
Multiple Control Options. The TST-3 uses an external J-housing to control the packer. This housing is currently
available in both left-hand and right-hand versions with; a J pattern, an L pattern, or an auto-J pattern. These J-
housings are easily changed out to allow the TST-3 to be tailored to fit the job that will be performed. Note: Right-
hand Auto-J control is recommended for Hurricane Plug or Storm Plug applications.
Reliable Setting. The slips on the TST-3 ride in a dovetail slot. This allows all of the slips to be deployed evenly
and flat against the casing. This serves to give the slips a more even bite while spreading the load more evenly to
the casing. This positive slip deployment also helps to center the packer within the tubulars allowing for more
reliable packoff. The slips and buttons use tungsten carbide inserts to reliably grip in all grades of casing and allow
penetration of scale and other buildup on the casing walls.
Reliable Release. Picking up the tubing string opens the bypass. This equalizes the pressure across the hydraulic
hold-downs to allow retrieval.
Proven Packing Element System. The packing element system used on the TST-3 is a robust, field proven system.
This system allows multiple sets, and may be tailored, through hardness selection or using alternate materials, to
meet a wide range of down-hole conditions.
Full Bore Design. Wireline tools and perforating equipment may be run through the tool while performing service
operations.
Keyed Mandrel Connections. The mandrel connections to both top and bottom subs are keyed to prevent back off
down hole.
Companion Equipment. The following BJ accessories may be used in conjunction with the 9-5/8 TST-3 Packer.
Confidential Proprietary Information

BJ Services Company, USA
COMPANION EQUIPMENT
Companion Tool Technical Unit Number

BJ Hurricane Valve 2103
BJ Rotational Equalizing Valve 2105
BJ Unloader Valve 2007
Storm Packer Bottom Guide 2107
SPECIFICATION GUIDE
TST-3 Specification Guide (all dimensions in inches)
Absolute Slip Absolute Button
Range Range
Casing Casing Casing ID Gauge Packing Min Max Min Max Spacer Ring Mandrel Standard
Size Weight Range Ring Element OD ID Connections
OD OD
9.6 47-53.5 8.535 - 8.681 8.218 7.937 8.220 8.760 8.130 9.073 8.168 3.00 3-1/2 EU or
4-1/2 IF
9.6 40-47 8.681 - 8.835 8.437 7.937 8.440 8.980 8.130 9.073 8.387 3.00 3-1/2 EU or
4-1/2 IF
9.6 29.3-36 8.921 - 9.063 8.593 8.375 8.580 9.120 8.130 9.073 8.543 3.00 3-1/2 EU or
4-1/2 IF
TOOL SIZE AND ASSEMBLY NUMBERS

9.6” TST-3 tool family selection chart:
Tool Size vs. J-housing pattern
With 3-1/2 EU connections (top and bottom)
Size RH J LH J RH L LH L RH Auto J LH Auto J

9.6 47 – 53.5# 80158-1 80158-4 80158-7 80158-10 80158-31 80158-34
9.6 40 – 47# 80158-2 80158-5 80158-8 80158-11 80158-32 80158-35
9.6 29.3 - 36# 80158-3 80158-6 80158-9 80158-12 80158-33 80158-36
With 4-1/2 IF connections (top and bottom)
Size RH J LH J RH L LH L RH Auto J LH Auto J

9.6 47 – 53.5# 80158-13 80158-16 80158-19 80158-22 80158-25 80158-28
9.6 40 – 47# 80158-14 80158-17 80158-20 80158-23 80158-26 80158-29
9.6 29.3 - 36# 80158-15 80158-18 80158-21 80158-24 80158-27 80158-30

PRESSURE, TEMPERATURE, AND MECHANICAL RATINGS

The standard TST-3 packer is shipped with a 90 Durometer Nitrile bypass seal and a 90-70-90 Durometer Nitrile
packing element system. All O-rings are Nitrile as well. This allows the packer to function appropriately in well
temperatures up to 275°F and at differential pressures up to 8,000 PSI (tubing or annulus pressure). Consult Service
Tools Engineering for optional 90 Durometer Bonded bypass seal and optional 90-80-90 durometer packing element
systems availability.
Packer Mechanical Limits
All values listed are with a safety factor of 1.0. If these values are exceeded, the packer must be disassembled and thoroughly
inspected for damage prior to returning the tool to service. It is recommended that if tensional loads are exceeded on the
mandrel, that the mandrel, top and bottom subs be replaced regardless of whether any damage is apparent.
9-5/8” TST-3 Packer Family (all packers with 80158-X for assembly numbers)
Mandrel – Maximum Tensile load 388,400 lb.
Mandrel and Top and Bottom Subs – Maximum Torque 28,630 ft-lb.
Mandrel – Minimum Burst and Collapse (in cases where the tubing is plugged) 17,500 PSI
Burst and Collapse – minimum for all pressure containing parts 8,000 PSI
Minimum tailpipe weight when used as a storm packer 62,500 LBS.
OPERATING INSTRUCTIONS
Prior to running
Make sure that the well is as clean as possible. Consult slack-off charts for specific combinations of tubing and
casing to make sure that enough set-down weight can be applied to the packer. Check hydraulic effects prior to
pressurizing the casing or starting the job. Make sure that there is enough set-down weight at the packer to hold the
bypass closed, and that the casing will withstand the treating pressures and packer induced forces. Make a fishing
diagram and note tool configuration (i.e. 9.6” 40-47# TST-3 with RH J). Verify that the tool ID is clear of
obstructions (run water from rig hose through the tool in sight of rig personnel, drift tool if necessary). Functional
test tool. Work drag block housing and J from running to set position, push J-housing toward packing elements and
verify free movement of all slips. Return the J to the running position. Make up TST-3 Service Packer and any
accessories to tubing or drill pipe. Verify that tool is in the running position. Verify that BOP is open.
Run tool to desired depth.
To Set
Note: Assume that a Right hand manual J tool will be used. (ex. 80158-1) All pipe movement stated will be what is
required at the tool.
Pick tool up 1 foot and rotate 1 turn to the right (clockwise as looking from the top of the draw works down at the
rig floor).
Slack off pipe weight to get at least the minimum set-down weight on the tool. (See set-down weight chart below)
Close the rams on the surface and pressurize the annulus to test for leaks. If pressure in the annulus can not be
maintained, the packer should be pulled and inspected.
Note: If the tool shows evidence of leaking when pressured from below due to insufficient set-down weight, pressure
the annulus (a few hundred PSI) to help the buttons retract before adding weight.

To Spot Fluids
After the tool has been tested, release any pressure on the tubing and then the annulus. Pick the tool up to open the
bypass, and unset the packer (if necessary). Begin spotting fluid. When the fluids are properly positioned, slack off
to set the packer and close the bypass. Apply proper weight to the tool. Monitor the annulus and tubing pressures
throughout the job.
To Release
After pressure is released from the tubing and annulus, if possible, the annulus should be pressured to a minimum of
two hundred PSI and held for at least 1 minute. This will help the hydraulic hold-down buttons retract. If
pressuring the back-side is not possible, it may be necessary to work the tool up and down slowly to help the buttons
retract. Releasing the tool and pulling from the hole too quickly (before the buttons can completely retract) can
seriously damage the tool and may damage casing.
Reversing Out
When squeezing and after setting sand plugs, when possible, reverse out. This helps to flush debris from the tool
and works to insure that the tool is free after job completion.
To Reset
The TST-3 can be set and released multiple times in the same trip to test casing or spot fluids at different locations .
If the tool has an “Automatic-J”, picking the tool up a few feet will put it in the running position. If a manual J or
manual L patterned control housing is being used, the tool may be pulled up the hole and reset simply by slacking
off weight. If it is to be run deeper into the well, the tool will have to be picked up a few feet, and rotated back into
the running position (if a RH J is used, the string should be turned LEFT 1 turn at the tool). The tool is now ready to
be run down hole and set as above.
Minimum Set-Down Weights Required for Packoff (all tool sizes) (lbs.)
Packing Element System Temperature Range 9.6 (all tool
(Durometers) (°F) sizes)(lbs.)
90-70-90 50-275 15,000
Note: Set Down weight is at the tool. Set Down weight required at surface will be higher.
Consumables
Description Part Number
Unloader Seal 90 Duro 80189-1
Unloader Seal Bonded 90 Duro 80160-1
Redress Kits:
O-rings 84917-1
Packing Elements 29.3-36 ppf 90-70-90 Duro 84918-1
Packing Elements 29.3-36 ppf 90-80-90 Duro 84918-2
Packing Elements 40-47 ppf 90-70-90 Duro 84918-3
Packing Elements 40-47 ppf 90-80-90 Duro 84918-4
Packing Elements 47-53.5 ppf 90-70-90 Duro 84918-5
Packing Elements 47-53.5 ppf 90-80-90 Duro 84918-6

TROUBLESHOOTING
Symptom Possible Cause(s) Possible Solution(s)
Packer will not start in hole 1) Drag blocks or gauge rings too large for 1a) Check gauge ring OD
casing 1b) Check drag blocks
1c) Verify tool appropriateness for
casing
2) Insufficient pipe weight 2) Add drill collars or pipe weight as
necessary
Packer hangs up going in hole 1) Packer trying to set 1) Pick tool up a couple of feet and
rotate back to running position
2) Trash in hole 2) POOH make bit / scraper run and
circulate 2 casing volumes to clean pipe
Packer will not set 1) Drag blocks not gripping 1a) Move up or down 1 joint to see if
packer will set
1b) Replace drag blocks and springs as
necessary
2) Slips not gripping 2a) POOH replace slips as necessary
2b) POOH inspect tool for debris
3) Wrong tool size 3) Verify tool appropriateness for
casing
Packer sets, but will not test 1) Packing elements too stiff for temperature 1) POOH and redress with correct
at depth packing elements
2) Packing elements damaged 2) POOH and redress with correct
packing elements
3) Insufficient set-down weight 3) Apply more set-down weight and re-
test
4) Damaged bypass seal 4) POOH and replace bypass seal
Packer leaks during job 1) Overpressure 1) Adjust treating and casing pressures
2) Tubing contraction 2) Apply more set-down weight
Packer will not retrieve 1) Buttons will not retract 1a) Slack off weight and pressure back-
side to push buttons back into receptacle
1b) Circulate through tool while pulling
tension
2) Tailpipe stuck in cement 2) Shoot off tailpipe and retrieve packer
Packer stops abruptly while 1) Packer trying to set 1) Pick tool up a couple of feet and
running rotate back to running position
2) Packing element trying to swab-off 2a) Run in at slower speed
2b) Use external circulation valve

ASSEMBLY LUBRICANTS
The lubricants listed below will provide adequate protection and lubrication for the TST-3 packers in land and
marine environments.
Grease Manufacturer
Liquid O-ring Polymer 400 Oil Center Research
ALCO EP Jet-Lube
CC Lube Jet-Lube
KOPR-KOTE Jet-Lube

CALCULATING HYDRAULIC FORCES ON THE TOOL

Effect of Tubing and Annulus Pressure on Unloader of TST-3
The Unloader Valve on the TST-3 is not hydraulically balanced for any particular tubing size. Therefore, changes in
tubing pressure and annulus pressure will exert a force
tending to open the unloader (by acting against tubing set-
down weight) or exert a force tending to hold the unloader
closed. The following material may be used to determine
the magnitude of these forces for a given change in tubing
or annulus pressure and also tell whether they are tending
to open or close the unloader.
The values given in the chart “Areas (in sq. ins.) Acted
upon By Tubing and Annulus Pressures” are printed as
positive or negative. These values are not only the
number of square inches acted upon by the pressure
change, but also the direction of the resultant force. The
figures shown as positive will cause, with a pressure
increase, a force tending to hold the unloader closed. The
areas shown negative will result in an upward force, or a
force tending to open the unloader. The directions of the
forces hold true if the tubing and annulus pressures at the
tool are increased.
If the tubing pressure at the tool is decreased, such as would occur in a swabbing operation, the direction of force as
explained above would be reversed.
When the annulus pressure is greater than tubing pressure, the Balance Piston is held by the annulus pressure,
against the Balance Piston Retainer. In this position, the Balance Piston does not act to help hold the Unloader
Valve closed; set-down weight alone must be used to keep the unloader closed.
It should be noted that the set-down weight required to keep the unloader closed need not be added to the weight
required to set the packer if the value calculated is less than the force required to set the tool.
Areas tending to close the unloader are positive. Areas tending to open the unloader are negative.
Multiplying a pressure change by a negative figure gives a force tending to open the unloader. Multiplying a
pressure change by a positive figure gives a force tending to hold the unloader closed.

TST-3 Packer and Hydraulic Data

Net Balance
Basic Packer Size Tubing Data Bypass Seal
Piston Area
Drill
Pipe Weight ID OD Area ID Area ID Area OD Area
Size Lbs./ft. In. (in2) (in2) (in.) (in2) (in2)
To Ti Si So Bn
6 5/8 25.20 5.965 34.471 27.945
5 7/8 23.40 5.153 27.11 20.855
5½ 24.70 4.670 23.758 17.128
9-5/8” – TST-3 5½ 21.90 4.778 23.758 17.930
5 25.60 4.000 19.635 12.560
5 19.50 4.276 19.635 14.360 14.22 16.76 14.50
5 16.25 4.408 19.635 15.261
4½ 22.82 3.500 15.900 9.621
4½ 20.00 3.640 15.900 10.406
4½ 16.60 3.826 15.900 11.497
4½ 13.75 3.958 15.900 12.304
For tubing dimensions, consult the “BJ Engineering Handbook”

Areas (in sq. ins.) Acted On By Tubing and Annulus Pressures
Tubing Pressure
Greater Than Annulus Pressure Annulus Pressure Greater
Annulus Pressure Greater Than Tubing Than Tubing Pressure At The
At The Tool Pressure At The Tool Tool
Tubing
Nominal Tool Tubing Weight Tubing Annulus I.D. Tubing Annulus
Size Size O.D. (lb/f) Area Area Area Area Annulus Area Tubing Area Area
Col. 1 Col. 2 Col. 3 Col. 4 Col. 5 Col. 6 Col. 7
6-5/8 -32.21 -20.25 -20.25

25.20 25.69 -27.95 13.73 -13.73
5-7/8 23.40 18.56 -24.81 -20.85 6.60 -12.86 -6.60 -12.86
24.70 14.87 -17.13 2.91 -2.91

5-1/2 -21.5 -9.54 -9.54
9-5/8” –TST-3 21.90 15.67 -17.93 3.71 -3.71
25.60 10.30 -12.56 -1.66 1.66
5 19.50 12.10 -17.38 -14.36 .14 -5.42 -.14 -5.42
16.25 13.0 -15.26 1.04 -1.04
22.82 7.36 -13.64 -9.62 -4.60 -1.68 4.60 -1.68
20.00 8.15 -10.41 -3.81 3.81
4-1/2
16.60 9.24 -11.50 -2.72 2.72
13.75 10.04 -12.30 -1.92 1.92
Where,
Column 1 = -(So-Ti) + (Bn)
Column 2 = (So-To) – (Bn) To = Tubing O.D. Area
Column 3 = -Ti Ti = Tubing I.D. Area
Column 4 = -(Si-Ti) So = Bypass Seal O.D. Area
Column 5 = Si-To Si = Bypass Seal I.D. Area
Column 6 = Si-Ti Bn = Net Balance Piston Area
Column 7 = Si-To
WHEN TUBING PRESSURE IS GREATER THAN ANNULUS PRESSURE AT THE TOOL:

Caution: Tubing movement calculation may be necessary to fully understand the forces on the packer and should be
run prior to the job.
1. Multiply the change in the tubing pressure at the tool by Column 1.

L1 = ΔP x Tubing Area Col. 1
2. Multiply the change in annulus pressure at the tool by Column 2.
L2 = ΔP1 x Annulus Area Col. 2
If the total of these forces is tending to open the unloader (negative), and is greater than the original pack-off
weight, additional set-down weight is required. This additional weight is equal to the difference between the
force tending to open the unloader and required pack-off weight.
3. Multiply the tubing pressure by Column 3.
L3 = ΔP x Tubing ID Area Col. 3
Since the figure in Column 3 is always negative, the resulting force is tending to open the unloader by lifting the
tubing at the surface. If by adding all three forces, the result is a force tending to open the unloader and is
greater than the maximum hook-load of the tubing before setting the tool, the tubing will raise and the unloader
will be opened. Since the hook-load is the limiting factor, high pressures at relatively shallow depths might be
prohibitive.
If L1 + L2 + L3<0 lb., tends to open the unloader valve. Add this to required set-down weight.
If L1 + L2 + L3>0 lb., tends to keep the unloader valve closed.
4. If the tubing is secured at the surface by a X-mas tree or such, the lifting force calculated instep 3 can be
disregarded.
Example Problem 1
Well Properties
9-5/8 53.5 ppf casing
5” – 19.50ppf drill pipe
9.0 lb/gal brine water – casing is full
ΔP = tubing pressure = 3000 psi at tool
ΔP1 = annulus pressure = 0 psi at tool
Set-down weight = 15,000 lb.

1. Multiply the change in the tubing pressure at the tool by Column 1.

L1 = ΔP x Tubing Area Col. 1 = 3000 psi x 12.10 sq. in. = 36,300 lb.
2. Multiply the change in annulus pressure at the tool by Column 2.

L2 = ΔP1 x Annulus Area Col. 2 = 0 psi x (-17.38) sq. in. = 0 lb.
L1 + L2 = 36,300 + 0 = 36,300 lb.>0 lb. (tends to keep unloader valve closed)
3. Multiply the tubing pressure by Column 3. (Tubing not secured at surface)

L3 = ΔP x Tubing ID Area Col. 3 = 3000 psi x (-14.36) = -43,080 lb.
4. Adding the forces,

L1 + L2 + L3 = (36,300 + 0 + -43,080) lb. = -6,780 lb., will tend to open the unloader seal.
Therefore, an additional 6780 lbs is needed for a total of 21,780 lbs to set the tool, and keep the unloader seal closed.
WHEN ANNULUS PRESSURE IS GREATER THAN TUBING PRESSURE AT THE TOOL:

1. Multiply the change in tubing pressure by Column 4.
2. Multiply the change in annulus pressure by Column 5.

If the total of these two forces is tending to open the unloader, and is greater than the original pack-off weight, additional set-
down weight is required. This additional weight is equal to the difference between the force tending to open the unloader and
the required pack-off weight.

L3 = ΔP x Tubing ID Area Col. 3
Since the figure in Column is always negative, the resulting force is tending to open the unloader by lifting the tubing at the
surface. If by adding all three forces, the result is a force tending to open the unloader and is greater than the maximum
hook-load of the tubing before setting the tool, the tubing will raise and the unloader will be opened. Since the hook-load is
the limiting factor, high pressures at relatively shallow depths might be prohibitive.
Example Problem 2
Same example as above, except now ΔP= 0 psi. and ΔP1 = 3000 psi.
L1 = ΔP x Tubing Area Col. 4 = 0 psi. x (.14 sq. in.) = 0 lbs.

L2 = ΔP1 x Annulus Area Col. 5 = 3000 psi x( –5.42) sq. in. = -16,260 lb.
L1 + L2 = 0 + (-16,260) = -16,260<0 (tends to open unloader valve).

L3 = ΔP x Tubing ID Area Col. 3 = 0 psi x (-14.36 sq. in.) = 0 lb.
In our case, L1 + L2 + L3 = (0 + (-16,260) + 0) lb. = -16,260 lb., will tend to open the unloader valve.
Therefore, a minimum of 15,000 lb. + 16,260 lb. = 31,260 lb. in order to set the tool and keep the unloader seal closed.

WHEN ANNULUS PRESSURE IS GREATER THAN TUBING PRESSURE AT THE TOOL DUE TO
SWABBING THE TUBING:

If the result is a force tending to open the unloader, and is greater than the original pack-off weight, additional set down
weight is required. This additional weight is equal to the difference between the force tending to open the unloader and the
required pack-off weight.
If L1 + L2 < 0, the unloader valve tends to open.
If L1 + L2 >0, the unloader valve tends to stay closed
Be sure to consult slack-off charts to determine whether the requisite amount of pipe weight can be put on the tool. If slack-
off weight is not sufficient, then drill collars may have to be used to put sufficient weight on the tool.
Consult tubing movement simulation to insure that treating (tubing ballooning, thermal movement, etc.) does not remove too
much of the initial pipe weight.
Example Problem 3
Same example as above, except now ΔP= 0 psi. and ΔP1 = 3000 psi. due to swab-off.

L1 = ΔP x Tubing Area Col. 6 = 0 psi x .14 sq. in. = 0 lb.

L2 = ΔP1 x Annulus Area Col. 7 = 3000 psi x –5.42 sq. in. = -16,260.
In this case, L1 + L2 = 0 lb. + (-16,260) = -16,260 lb., will tend to open the unloader.
Therefore an additional 16,260 lbs will need to be added to the setdown weight for a total of 31,260 lbs to set the packer, and
keep the unloader seal closed.

9.6” 29.3-53.5 PPF TST-3 ASSEMBLY INSTRUCTIONS

The 9.6” TST-3 Packer is configured to run in three weight ranges: 29.3-36ppf, 40-47ppf, and 47-53.5ppf. There
are three sets each of gauge, guide, and spacer rings and two sets each of end and center elements. Identify the
casing size, weight and element system to be used and dress the packer accordingly. Please refer to the 9.6” TST-3
Assembly Part Numbers (page 17) and Parts List (pages 18-21) for the correct parts for the different tool
configurations.
Check all parts for wear or damage. Replace any part that shows significant wear or other damage. All parts should
be clean and free of rust. Remove any wrench marks with a file or emery cloth. Remove and discard any old or
used rubber goods. Use only rubber goods that are within shelf life and storage requirements. Rubber goods must
conform to BJ Specification 265203. Use only Downhole Tools approved thread and o-ring lubricants. See
“Assembly Lubricants” section for approved lubricants.
All threaded parts should make up smoothly. If not, have the parts inspected.
Tools Needed:
• 3/16, 1/8 allen wrenches (ball end recommended),
• 2 pipe wrenches capable of gripping 2” pipe through 7” pipe,
• brass hammer (approx. 6 oz.),
• small pry-bar or punch (approx. 10” long and up to ½” dia.),
• 2 lb. dead blow hammer,
• small non-marring hammer.
• Collet Assembly Tool (P/N 87694-1)
Do’s and Don’ts for TST-3 Packer Assembly and Disassembly

DO DON’T
Use the recommended lubricants for straight threads and o- Substitute other greases without approval from Service
rings in this technical unit. Tools Engineering.
Visually inspect all parts prior to assembly and after Use parts that are damaged or repaired without consulting
disassembly. with Service Tools Engineering.
Visually inspect parts after installing o-rings. Use the packer if evidence of o-ring damage is present.
Use cranes, lifting bolts and heavy duty vises. Assemble or disassemble packer without lifting aids and
vises.
Discard all used seals, including the bypass seal after the Re-use any rubber seals that have been run into the well.
packer has been run.
Always use new seals within shelf life requirements at Use seals that have been in the well or are out of shelf life.
redress.
ASSEMBLY:
1. Install o-ring (19) in balance piston (9) using Downhole Tools approved lubricant. Apply lubricant to the OD
of the balance piston around the O-ring and the sliding seal area.
2. Lubricate the ID of the balance piston retainer (8). Slide the balance piston (9), o-ring end first, into the balance
piston retainer (8). Press the balance piston in until it bottoms in the balance piston retainer
3. Slide the balance piston (9) and the balance piston retainer (8) over the top of the mandrel (7) until the balance
piston (9) contacts the lugs on the mandrel (7).

4. Lubricate bypass seal (5) and install in bypass seal retainer (3).
5. Slide bypass seal (5) and bypass seal retainer (3) over the top of the mandrel (7) until the bypass seal retainer
(3) is close to the balance sleeve retainer (8). If the bypass seal (5) has become dislodged from the bypass seal
retainer (3) push the bypass seal (5) back into position.
6. Lubricate the O-ring groove on the top of the mandrel (7) and install the O-ring (18). Apply thread lubricant to
the threads.
7. Lubricate the seal area on the inside of the top sub (1-2). Screw the top sub (1-2) onto the mandrel (7) until it is
hand tight. Back the top sub (1-2) off until the key slots in the top sub (1-2) line up with the key slots in the
mandrel (7).
8. Begin threading the bypass seal retainer (3) on to the top sub (1-2). When the bypass seal retainer (3) is near
the key slots in the top sub (1-2), place the keys (4) in the slots. Be sure that the keys (4) seat fully. The tops of
the keys (4) should be below the threads on the top sub (1-2). Finish screwing the bypass seal retainer (3) on.
Make sure that the bypass seal (5) is properly positioned. Tighten the bypass seal retainer (3).
Note: there may be a small gap on the OD where the bypass seal retainer (3) and the top sub (1-2)
meet. This is acceptable, as the bypass seal retainer (3) is designed to shoulder on the ID to help
hold the bypass seal (5). Remove any wrench marks with a file or emery cloth.
9. Lubricate and install O-ring (20) in receptacle (10).

10. Apply thread lubricant to all threads on the receptacle (10). Measure the OD of the guide ring (12-14) and
make sure that it is no more than 0.020” smaller than the nominal OD for the tool size being assembled (e.g.
8.437” nominal OD for a 9.6” 40-47 ppf tool. A measured OD less than 8.417 makes the guide ring bad, and
must be replaced.). Screw on and tighten guide ring (12-14).
11. Measure upper gauge ring (24-26). If measured OD is smaller than nominal OD less 0.020, discard and replace
upper gauge ring (24-26). Screw on and make tight to receptacle (10). Note: This is a LEFT-HAND thread.
12. Inspect the collet (35) fingers. Make sure that they are not bent, scarred, or unduly worn. All of the fingers
should be the same width, same length, and form a smooth circle when viewed from the end. If the fingers are
bent, stretched, or otherwise damaged, the collet (35) must be replaced. Lubricate OD of collet (35) including
the O-ring seal surface, thread and packing element sleeve. Install O-ring (22).
13. Measure lower gauge ring (37-39). If measured OD is smaller than nominal OD less 0.020, discard and replace
lower gauge ring (37-39). Slide the lower gauge ring (37-39) over the packing element sleeve on the collet
(35). The threads in the lower gauge ring (37-39) should overhang the collet (35) fingers.
14. Slide an end element (27-28) over the packing element mandrel of the collet (35) and press against lower gauge
ring (37-39). Be sure that packing elements are provided with proper traceability information. This is to
include Batch number and Cure date.
15. Measure the OD of the packing element spacers (30-32). If they are out of tolerance, or otherwise damaged
(bent, nicked, pitted) they should be replaced.
16. Slide a packing element spacer ring (30-32) on to the collet (35). Follow this with the center packing element
(33-34). Note: There is a raised ring on the ID of most center elements. This ring should be toward the
Fingers of the collet (35).
17. Slide on the second packing element spacer ring (30-32) followed by the final end element (27-28).

18. Make sure that the O-ring (22) is in place on the collet (35) and screw the collet (35) and element stack into
place on the receptacle (10). Use Collet Assembly Tool (P/N 87694-1) to avoid damaging collet fingers during
assembly or disassembly. Refer to the below illustration for assembly directions. Slide the Assembly Tool over
the collet (35) fingers and tighten collet (35) by wrenching on Collet Assembly Tool body. When finished,
remove Collet Assembly Tool before continuing with assembly of packer.
19. Slide the receptacle (10) and collet (35) assembly on from the bottom of the mandrel (7). The collet (35)
fingers will fit tightly around the mandrel (7) and may drag across the threads as it is installed. This is normal.
The collet (35) should be able to be pushed over the mandrel (7) threads and other “wide spots” on the mandrel
(7) with little difficulty. DO NOT hammer on the collet (35) fingers or on the receptacle (10) as this will
damage or destroy these parts.
20. Carefully slide the end of the receptacle (10) over the lugs on the mandrel (7). If necessary, re-lubricate the
threads on the top of the receptacle (10), and thread on the balance piston retainer (8). Screw this on carefully,
and do not force or over-torque during installation. The balance piston (9) is working its way into the seal area
in the receptacle (10). If this does not screw together easily, back the balance sleeve retainer (8) off, and make
sure that the balance piston (9) is centered and pushed to the top of the balance piston retainer (8), and try again
to thread the parts together. Make the balance piston retainer (8) up tight to the receptacle (10). Remove any
wrench marks with a file or emery cloth.
BUTTON INSTALLATION
21. Apply a thin film of lubricant to one of the button holes in the receptacle (10).
22. Apply a thin film of lubricant to the O-ring (21), and install into the groove on the button (17). Apply a thin
film of lubricant to the OD of the button (17).
23. Place the button (17) in the lubricated bore of the receptacle (10). Rotate the button (17) so that the slot aligns
with the slot in the receptacle (10), and the flats on the carbide inserts point toward the bottom of the tool
(toward the Packing elements). Carefully work the button into the hole, taking care not to cut the o-ring (21). If
necessary the button (17) may be tapped with a non-marring hammer. Do not use a steel hammer, as this will
destroy the carbide inserts. If a sliver of rubber was cut from the o-ring (21), or you suspect that the o-ring (21)
was damaged, remove the button (17) inspect the o-ring (21). If the o-ring (21) is damaged, it must be replaced.
24. If necessary, rotate the button (17) such that the slot through the button (17) lines up with the slot on the
receptacle (10) OD, and the flat faces on the carbide inserts face the bottom of the tool.
25. Prepare and install the button (17) next to this last one in the same manner as the first button (17). Again be
sure that the O-ring (21) is in good condition, and the button (17) is oriented correctly. Check for shreds of
rubber after installing each button (17). This is evidence of O-ring damage. Replace damaged O-rings
immediately and re-install buttons (17) carefully. Persistent damage to O-rings at installation is evidence of bad
installation practice or non-conforming buttons (17) or receptacle (10).
26. Place a spring (23) in each of the flat bottom holes in the bottom of the slot in the buttons (17). There should be
two (2) springs (23) per button (17).
27. Place the piston retainer (16) strap in the slot in the receptacle (10) OD, covering the springs (23) in the buttons
(17). Lubricate and secure in place with the countersunk socket head screws (15).
28. Repeat with the other three rows of buttons (17).
29. Lubricate the threads on the packer actuator body (40) and the cone (41-43) and screw together.
30. Stand the cone (41-43) and packer actuator body (40) vertically with the slots in the cone (41-43) pointing up.
Hang the slips (44) in the slip retainer ring (46) and lower the slips (44) into the slots in the cone (41-43).
31. Lubricate the saddle ring groove on the slip retainer ring (46).
32. Lubricate the threads on the drag block housing (50) and screw the saddle sleeve retaining ring (48) on until the
saddle sleeve groove is exposed. Lubricate the saddle sleeve groove.
33. Place the dragblock housing (50) on the slip retaining ring (46).
34. Install the saddle ring (47).
35. Slide the saddle ring retainer (48) down over the saddle ring (47) and screw down until the holes in the retainer
ring (48) line up with the groove in the dragblock housing (50).
36. Install the retaining screws (49).
37. Install the connector sleeve (45) down the center of the cone (41-43)/dragblock housing (50) assembly. The
connector sleeve (45) screws into the cone (41-43). Make connector sleeve (45) tight.
Note: If the connector sleeve is not tight, it could unscrew and allow the slips (44) to fall out.
38. Slide the cone (41-43)/dragblock housing (50) over the mandrel (7) and make tight to the bottom gauge ring
(37-39).
39. Grease the internal threads, seal area, and the sleeve area on the bottom sub (68-69).
40. Slide the key retaining sleeve (67) onto the bottom sub (68-69). The holes should be on the end closest to the
end of the bottom sub (68-69).
41. Lubricate the O-ring groove on the bottom of the mandrel (7) and install the O-ring (70).
42. Screw the bottom sub (68-69) onto the mandrel (7) until it butts up tight. Loosen the bottom sub (68-69) until
the key slots align with the slots in the mandrel (7). Insert the keys (73).
43. With the keys (73) completely seated, rotate the key retaining sleeve (67) 45°, until the screw holes align and
install the retaining screws (66).
44. Place 4 springs (52) into the pocket on the underside of the dragblock (51).

45. Slide the dragblock (51) and springs (52) into the dragblock housing (50). Repeat for the other five (5)
dragblocks (51).
46. Slide the j-housing (54-65) over the bottom sub (68-69). Align the slots in the j-housing (54-65) with the lug on
the bottom sub (68-69) and slide the j-housing (54-65) over the j-lug on the bottom sub (68-69). Slide the drag
block housing (50) down to meet the j-slot housing (54-65) and screw the two together. Note, this is a left-hand
thread. Make tight and install the setscrews (53). Check the drag blocks (51) for free movement.
47. Rotate the J-housing (54-65) from the set position to the running position a couple of times to insure free
movement of the dragblock housing (50) and J-housing (54-65). Move the J-slot to the setting position and
push the assembly upward (toward the top sub (1/2)). Make sure that the slips (44) come out easily, and remain
in the cone (41-43) and slip retainer (46). Pull J-housing (54-65) down (toward bottom sub (68-69)) firmly and
make sure that the slips (44) stay in the cone (41-43). Move the J-slot back to the running position.
Note: A guide ring (71) is not used on the 3-1/2” IF bottom sub (69).
48. Apply lubricant to the guide ring threads on the bottom sub (68-69). Slide the guide ring (71) on over the
bottom sub (68) and thread onto the threads. Make tight and install the retaining setscrews (72).
49. Lubricate the threads on the bottom of the bottom sub (68-69) and install a thread protector.
50. Lubricate the box connection on the top sub (1-2) and install a thread protector. Note: This is sufficient only
for indoor storage. If the tool is to be stored outdoors, appropriate measures must be taken to prevent corrosion
of the mandrel (7) ID as well as the outer parts.
51. Wrap the packing elements in paper and tape in place. Wrap paper thickly and tape securely. Mark casing OD
and weight that tool is dressed for (e.g. 9.6” 40-47 PPF).

9.6” TST-3 ASSEMBLY PART NUMBERS

Index No: 2026 Revision: J Date: December 4, 2007 Page 18 of 26
9.6” TST-3 PARTS LIST






9.6” TST-3 ASSEMBLY VIEW

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

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


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BJ SERVICES COMPANY, USA

Service Tools Technical Manual

TST-3 SERVICE PACKER - 9.63” 29.3-53.5 PPF

FEATURES AND BENEFITS

Confidential Proprietary Information

Companion Tool Technical Unit Number

TOOL SIZE AND ASSEMBLY NUMBERS

Size RH J LH J RH L LH L RH Auto J LH Auto J

With 4-1/2 IF connections (top and bottom)

Size RH J LH J RH L LH L RH Auto J LH Auto J

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PRESSURE, TEMPERATURE, AND MECHANICAL RATINGS

Confidential Proprietary Information

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CALCULATING HYDRAULIC FORCES ON THE TOOL

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TST-3 Packer and Hydraulic Data

For tubing dimensions, consult the “BJ Engineering Handbook”

6-5/8 -32.21 -20.25 -20.25

5-7/8 23.40 18.56 -24.81 -20.85 6.60 -12.86 -6.60 -12.86

24.70 14.87 -17.13 2.91 -2.91

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

1. Multiply the change in the tubing pressure at the tool by Column 1.

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1. Multiply the change in the tubing pressure at the tool by Column 1.

2. Multiply the change in annulus pressure at the tool by Column 2.

3. Multiply the tubing pressure by Column 3. (Tubing not secured at surface)

4. Adding the forces,

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

2. Multiply the change in annulus pressure by Column 5.

3. Multiply the tubing pressure by Column 3.

2. Multiply the change in annulus pressure by Column 5.

3. Multiply the tubing pressure by Column 3.

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2. Multiply the change in annulus pressure by Column 7.

1. Multiply the change in tubing pressure by Column 6.

2. Multiply the change in annulus pressure by Column 7.

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9.6” 29.3-53.5 PPF TST-3 ASSEMBLY INSTRUCTIONS

Do’s and Don’ts for TST-3 Packer Assembly and Disassembly

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

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9.6” TST-3 ASSEMBLY PART NUMBERS

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9.6” TST-3 PARTS LIST

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9.6” TST-3 ASSEMBLY VIEW

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

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

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