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    OTe 6459Field Use of Thru-Tubing Electric Wireline SetBridge Plug SystemL.E. Mendez, M.P. Coronado, and D.J. Holder, Baker Service Tools

    Copyright 1990, Offshore Technology ConferenceThis paper was presented at the 22nd Annual OTC in Houston, Texas, May 7-10, 1990.This paper was selected for presentation by the OTC Program Committee following review.of information. contained in an abstract s U b ~ i t t e d by the author(s). Contents of the paper,as presented, have not been reviewed by the Offshore Technology Conference and are subject to correction by the author(s). The matenal, as presented, does not necessanl.y renectany position of the Offshore Technology Conference or its officers. Permission to copy is restricted to an abstract of not more than 300 words. illustrations may not be copied. Theabstract should contain conspicuous acknowledgment of where and by whom the paper IS presented.

    INTRODUCTIONABSTRACT

    A new electr ic wireline through-tubing inflatablebridge plug system has been developed which allowseither permanent or retrievable bridge plugs to berun through th e tubing str ing and set in large diameter casing below without th e use of a workoverr ig. The system employs a downhole electric pumpto f i l ter and pressurize wellbore fluid f or b ri dg eplug inflat ion. After pressurization, th e bridgeplug can handle h igh differential pressures withoutthe aid of sand or cement. The system is conveyedand powered by a conventional electr ic wirelineunit .The paper will discuss development of th e system,system components and comparison of design andperformance characterist ics with those provided byconventional bridge p lug sys tems .The paper addresses possible savings in costs andtime as well as ease of performing well operationswhen th e system is used to accomplish: 1) select ive stimulation, including acidizing, fracturingor other chemical treatments; 2) select ive watershutoff within a producing zone or the total abandonment of a p roducing zone , i .e . perform aworkover without kill ing the well.The authors have been instrumental in the development of this system and with i ts subsequent success fu l appl ica t ion in Prudhoe Bay. The authorswill discuss f ield history and provide details andinsights on operational procedures, applicationsand system limitations.

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    The pursuit of technology to reduce productioncosts has changed tradit ional methods of wellworkover, maintenance, and stimulation. Performingrequired well service through tubing is now com-monplace in several a reas around th e world. Priorto th e advent of through- tub ing wel l operations,any workover or well stimulation meant moving in aworkover rig , k ill in g the well and pulling production tubing. The production packer was removed,required work performed and th e well recompleted.Before development of th e new workover system discussed in this paper, th e average operation atPrudhoe Bay, Alaska required about 21 days.In 1987, inflatable packers and plugs that couldbe run on coiled tubing through th e productiontubing were introduced in Prudhoe Bay. By eliminating the workover r ig and all ancillary operations required by conventional workovers,through-tubing servicing allowed wells to be returned to production in signif icantly less time.The inflatable packers and bridge plugs had im-proved expansion charac te r is t ic s d i ct at ed by th erigors of going through tubing and sett ing in th ecasing below without sacrif icing pressure holdingcapabili ty . Today, inflatable packers and plugsrun on coiled tubing a re r ou ti nel y util ized inPrudhoe Bay to perform select ive stimulation andinterval shut-offs.Complementing this equipment and evolving throughtubing technology even further is a new electricwireline through-tubing inflatable bridge plugsystem. The new system (Fig. 1) allows, withoutthe use of a workover r ig , ei ther permanent ortemporary bridge plugs to be run through th e tubingstring and set in large diameter casing below. Thesystem employs a downhole electr ic pump system tofilter and pressurize wellbore fluid for bridgeplug inflat ion. After sett ing, th e bridge plug is

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    Field Use of Through-Tubing Electric Wirel ine Set Bridge P lug Systemcapable of withstanding high differential pressures. The system is conveyed and powered by aconventional electr ic wireline unit (Fig. 2) .This paper addresses th e development of this systemand th e recent f ie ld t es ti ng in Prudhoe Bay.SYSTEM DESCRIPTION AND BASIC OPERATIONThe new system is composed of an inflatable bridgeplug and a setting tool (downhole pump). A powersupply a t th e s urf ac e furn ishes electr ical powerthrough a conventional electr ic wireline unit. Thetwo components of the system were developed independently and la ter integrated. The bridge pluguti l ized was ini t ia l ly developed fo r use withcoiled tubing and was an adapt at io n o f existinginflatable bridge plug technology. Various meth-ods of sett ing a bridge plug on wire l ine throughtubing were investigated before selection of thedownhole pump concept.The bridge plug uti l ized in this system has beenproved in coiled tubing applications. As necessitated by going through tubing and sett ing in thelarger diameter casing, the plug may be requiredto expand to more than 300 percent of i ts originaldiameter and s t i l l withs tand h igh pressure andtemperature. The plug returns to i ts original diameter for retrieval through th e tubing. I t issingle t r ip wireline retrievable. The small diam-eter of th e top section of the bridge plug facil i-tates washover operations and retrieval on coiledtubing.After a surface test check of th e sett ing tool, thebridge plug and setting tool are run to desiredsetting depth (Fig. 3A). Electrical power is thenprovided at the su rfa ce and conveyed through th ewir el in e t o th e sett ing tool. The operation modesof th e system are tracked by monitoring amperagedraw of th e system a t surface. Ini t ia l amperagedraw during inflation of the bridge plug (Fig. 3B)will denote operation of th e sett ing tool and thatth e inf lat ion sequence has been initiated. A rapidincrease in amperage draw (Fig. 3C) signals thatth e bridge plug has been inflated and thatpressurization is occurring. The disconnect se quence of the system (Fig. 3D) is accompanied by asharp drop in amperage draw at t he s ur fa ce . Thesetting tool and wireline are then free to be retrieved. The set bridge plug is capable of holdinghigh differential pressures without th e aid of asand or cement barrier (Table 1).BRIDGE PLUG DEVELOPMENTIn 1986, development began on an inf latable bridgeplug system capable of being run through productiontubing and set in the product ion casing below. Thesystem required a plug that was: 1) capable ofbeing run on coiled tubing, 2) wireline retr ievable, 3) rated at 2500 psi (17,235 kPa) a t 280F.(l38C.) in 7.0-in. (l77.8mm) OD casing, and 4)3.38-in. (85.8mm) OD. The plug was hydraulicallyset and released with a straight pull mechanism.Circulation through th e plug going in the ho le wasaccomplished with a bottom valve in the plug. Thebridge plug was set by uti l iz ing a ball insertedinto th e coi l tubing reel and circulated to a seat

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    OTe 6459in the plug. After th e ball was seated, hydraulicpressure applied at th e surface closed the circulation valve and the plug inf lated. Premature in f lat ion was prevented by a piston valve securedwith shear screws. The screws were designed toshear a t a preset pressure, allowing piston move-ment and inflation. A similar mechanism on to p ofth e bri dge p lug allowed th e coiled tubing to disconnect from th e tool af ter inflation. The coiledtubing could then be tripped or used to pumptreatment fluids.Wireline retrieval of th e plug, as ini t ia l ly de signed, was accomplished in two steps. Firs t , th edifferential pressure across th e plug was equalizedby latching a wirel ine pu ll ing tool to th e equalizing mandrel on th e plug and pulling i t from th ewell. The equalized plug remained inflated and inplace. A second wireline t r ip was made to latchonto a second fishing neck on the plug and allowedth e plug to be released and deflated with upwardmotion.The plug also featured an emergency disconnectmechanism which would allow th e coiled tubing tobe released from th e plug i f th e plug should becomestuck in the hole. This was accomplished by cir -culating a ball (larger diameter than se tt ing ba ll )through th e coiled tubing to a seat in th e hydraul ic disconnect on top of the plug. Hydraulicpressure applied through t he c oi le d tubing shiftedth e p is to n i n th e disconnect and r el ea se d t he tu bin g from the plug. The p lug cou ld then be fishedwith a wireline tool.BRIDGE PLUG FIELD TESTINGField test ing of th e coiled tubing bridge plug began in th e Prudhoe Bay field in February of 1987.Ini t ia l success rates were low due to distort ionof th e e lemen t a s the b ridge p lug was being runthrough th e production tubing, excessive pressuredifferentials and incorrect plug placement .Fluid bypass around th e plug as i t was being runthrough th e product ion tubing was restric ted andwould cause th e inflatable element (Fig. 1) on th eplug to sl ide up on th e interior mandrel and resultin swaboff. The bottom of th e element was unancho red becau se of r equi red r educ ti on in axiall ength dur ing inf lat ion. The bridge plug was re des igned wit h a shear assembly instal led in thebottom of the element which would keep th e elementin a stretched, streamlined position as i t movedthrough th e production tubing. Upon inf lat ion ofth e element, th e shear assembly released to permitaxial element movement.Failure occurred in production well s when settingplugs fo r water shutoff jobs due to element deformation resulting from pressure fluctuations. Thiselement deformation led to increased internal volume of th e element. This res ulte d in decreasedinflation pressure which in turn rendered th e plugineffective. The problem was solved by Prudhoe BayUnit Operators placing calcium carbonate or an acidsoluble cement on top of th e plug prior to r etu rn ing th e well to production. This mechanical barr ier prevented element distortion during th epressure cycles and increased success rates of theplug in this application.

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    OTC 6459 Luis E. Mendez, Martin P. Coronado and Danny J . Holder 3

    Error in depth lo ca tio n co ntrib ute d to fai lures in ce t he target in these cases was a short sectionof blank pipe and th e error placed th e plug in theperforations. The in i t ia l plug would not holdpressure in these si tuat ions. Also, retrieval ofth e in i t ia l plug after a frac jo b was very diff i -cult . The 3-3/8-in. (85.8mm) OD of th e tool prevented washover of the plug to th e element.Approximately 36-in. (9l4.4mm) of sand would remain on top of the element and hamper plug retr ieval. This washover problem could no t easilybe corrected with th e in i t ia l plug design.The problems inherent with th e in i t ia l plug whenset in perforations and in retrieval necessitateda second generation plug design. This new designhad a stronger element capable of maintaining integri ty when set in pe rfo ra tion s. It could alsobe washed over and retrieved on coil tubing. Thesuperiority of th e new element was due to increasedmechanical strength and better e la stomer proper t ies . Utiliz ing this new element, th e plug was nowcapable of set t ing i n 9 .63- in . (244.6mm) 00 casing{original design cr i ter ia was 7-in. (177 .8mm) ODcasing} and holding 1500 psi (13,788 kPa) a t225F. (107C.). The new plug was also designedwith a 3.0-in. (76.2mm) 00 and featured a 2.38-in.(60.5mm) OD to p section. This small OD facil i tatedwashover and retrieval operations.The second generation plug also was designed to beretrieved in one t r ip . Plug equalization,defla tion and retrieval was accomplished on th esame t r ip . The plug was developed in both retrievable and permanent versions.SETTING TOOL DEVELOPMENTDevelopment work on th e setting to ol a lso began in1986. This project proceeded at a signif icantlyslower pace than that of th e bridge plug. Conceptsexamined were: 1) inflat ing th e plugs withchemically generated foams; 2) carrying inflat ionfluids downhole powered with gas generating devicesor an electr ic driven downhole pump; and 3) anelectr ic pump that would inf la te the plug with th edownhole wellbore fluids. Temperatures and pressures eliminated th e chemical methods. Carryingth e necessary volume of fluids downhole was im-pract ical due to th e length of t oo l r equi red. Theelectric pump util izing downhole wellbore fluidswas judged th e most feasible concept.Research and lab test ing was required to determineparameters fo r th e sett ing tool. The limitedamount of power that could be transmitted througha conventional electr ic l ine, the dimensional constraints dictated by tubing size and pract icallubricator length, inflat ion time limitations, andpumping wellbore fluids at downhole temperaturesand pressures posed major design problems. Thereis an abundance of equipment on the market designedto accomplish th e different functions required ofth e setting tool. However, this available equipment generally was designed fo r low pressures andtemperatures, required excessive power, and was to olarge. In most cases the equipment cou ld only pumpclean fluids with good lubrication properties.The new setting tool components were designed foroptimum electrical and mechanical power efficiency.

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    Voltage, amperage, torque, RPM, flowrate, andpressure were optimized to meet th e design requirements. The equipment made use of materialsin unique app li ca ti on s t o enable operation in awellbore environment without sacrif icing rel iabi li ty and durabil i ty.LOCATING AT DEPTHPlacing th e bridge plug in the correct location ishighly cr i t ica l in many instances. Correct placement of th e bridge plug could be th e only difference between success or fai lure. Production zonesin Alaska may only be 10 feet apart in some wells.With coiled tubing se t bridge plugs, setting depthcou ld be off by as much as 20 f t . (6.1m) per 10,000f t . (3,048m). Blank pipe targets less than 40 f t .(12.2m) in length are no t pract ical without adownhole reference point. A mechanical tubing endlocator can improve setting depth location by pro-viding a downhole reference point. This locatorprovides a 3000 lb. (1,361 kg) indication on th eweight indicator when pulled through th e end ofproduct ion tubing or landing nipples. This signalis generated by compression of leaf spr ings incor porated in the locator as i t is pulled back intoth e tubing. Depth correlation of the tubing tai lis then made with t he wir el ine log of the well.Coiled tubing e longa tion must also be consideredwhen util izing a mechanical tubing end locator.The additional force required above tubing weightinherently adds length to th e string. 1 Pressuringth e coil tubing causes both elongation and contraction in the tubing during the sett ing processof th e plug. 2Setting th e bridge p lug with a wireline sys tem doesno t have the location problems associated withcoiled tubing. A convent ional shoot ing collar locator is run with t he wi re li ne bridge p lug sys tem.The collar locator is modified to allow power tobe carried through to th e sett ing tool. Thismethod of location allows more precise depth cont rol . I t is obviously easier to correlate betweenwireline logs than correlate a coiled tubing stringto a wireline log. In addition, th e wells areu su ally p er fo ra te d after correlation with awire line collar locator. The bridge plug can beplaced more a ccur at el y i n short intervals betweenperforations i f th e same method of location isused.UTILIZATIONThe bridge plug system has been successfully uti-lized in selective production and in je c tion appl ications where temporary or permanent s hu t- of f o fproduct ion casing is required. These applicationsinclude:1. Shutoff of a lower water producing zone;2. Isolation of lower producing intervals fo r gasshutoff cement squeeze programs;3. Isolation of lower intervals for selective acidstimulation of upper intervals;

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    4. Isolation of the primary producing zone for for running the bridge plugs were: fracturing (4stimulation of a new upper zone by means of timee); acidizing (4 times); interval (water, gas)hydraulic fracturing; shut-off (4 times); and cement squeeze (2 times).

    5. Isolation of lower perforations in an injection The 14 wells had the following profiles: 7-in. ODwell for the purpose of changing the injection (177.8mm) casing with 4-1/2-in. tubing (114.3mm)profile of a well. or 5-1/2-in. (139.7mm) tubing with 4-1/2-intailpipe; 3.725-in. (94.6mm) minimum ID re-

    in water shut-off applications, a permanent or re-trievable bridge plug ia placed between productionzones. If a permanent plug is used, cement isgenerally placed on top of the plug to insurelong-term seal integrity. In retrievable applica-tions, either calcium carbonate or acid solublecement is placed above the plug. Both are easilyremoved with acid from the top of the plug for plugretrieval.In cement squeeze applications, calcium carbonateand aand are placed on top of the bridge plug.Coiled tubing is then used to squeeze the well andthen subsequently utilized to retrieve tbe plug.A downhole drilling motor and underreamer can berun on coiled tubing through the production tubingto remove cement bridges and nodes above the plugbefore retrieval.Selective acidizing jobs have been completed suc-cessfully utilizing a bridge plug in conjunctionwith a through-tubing packer run on coiled tubing.A bridge plug is run in and set below the treatmentinterval. The packer is then set above the inter-val. Treatment fluids are pumped down the coiledtubing and below the packer into the zone. Afterdisplacement of fluids into the formation. thepacker is pulled and the treated zone is pu{ backon production. The plug is retrieved later. Inthis application, a plug set with electric wirelineprovides better depth control and thus ensure bet-ter placement of treatment fluids.Another application of the bridge plug is forfracturing of a production zone. Once again theplug is set below the zone that is to be fractured.Frac sand is pumped down the production tubing andinto the formation. With sand placed above thebridge plug, differential pressures of more than5000 psi (34,47o kPa) have been applied across theplug when set in 7.0 -in. (177.8mm) casing. Oncethe frac is complete, sand is washed off of the plugand it is retrieved with coiled tubing (Fig. 3F).

    striction; 22-54 well deviation; and 180-228F.(82.2-93.3C.) well temperature. The range ofsetting depth for the plugs waa 8,181 ft.(2,493m)to 11,458 ft. (3,492m).The typical bridge plug system hook-up consistedof a 1.43-in. (36.3mm) OD cable head, 1.69-in.(42,9mm) OD collar or 3.25-in. (82.6mm) OD weightbars, 1.69-in. (42.9mm) OD collar locator, 2.O-in.(50.8mm) OD setting tool and 3.O-in. (76.2mm) or3.38-in. (85.9mm) OD bridge plug. The approximatelength of the hookup was 25 ft. (7.62m). Thesyatemwas usually run on approximately 19,000 ft.(5,791m) of .312-in. (7.9mm) OD electric wireline.However, there were several plugs set on approxi-mately 23,000 ft. (7,010m) of .218-in. (5.5mm) ODelectric wireline.Setting the plugs on the .218-in (5.5mm) OD cablewas accomplished despite larger power loss in thesmall line. The power losses in the .218-in.(5.5mm) OD line were approximately twice that ofthe .312-in, (7.9mm) OD line. It is thereforepreferable to run these tools on the larger cable.However, other considerations such as well condi-tions and/or cable availability may dictate choiceof cable size.Conveyed power to the electric pump was providedat the surface with a power supply which in turnwaa typically powered by a 6 kilowatt generator onthe wireline unit. There was never a problem withelectric shorting in any of the equipment at anytime. However, in several instances, the powersupply strained to provide the power demanded bythe electric pump at the peak of the duty cycle.The respective equipment manufacturers have offeredthree possible reasons for the power problems: 1)inferior condition of alternating current; 2)generator load was initially too low; and 3) designfor AC po,wer rectification of power supply wascreating peak AC power demands in excess of gener-ator capacity. New equipment is being evaluatedto correct this problem.

    Modification of a wells injection profile can be Average setting time required to set the bridgeaccomplished by setting a bridge plug above a thiefzone and prohibiting flow into that zone. This plug was 1.25 hours. The setting time was a func-altered injection profile provides a more uniform tion of cable diameter and length, wellbore fluidssweep of the reservoir. Through-tubing bridge and the required pump pressure output.plugs have been used in this application with both

    IAll plugs set were correctly located with the ex-

    water and miscible gas as the injection medium. ception of one, which was retrieved. On that well,Compatibility of the electric line bridge plug it-was theorized that crossflow between zones wassystem with offshore operations should also be moving the plug before it was fully set. The plugconsidered. Little or no equipment is required was successfully set by locating it lower in theblank interval (allowance for umer movement) andthat ia not generally available for other oper- 1 ..using heavier weight bara,ations. LIMITATIONS AND FUTURE D VELWThe through-tubing wireline inflatable bridge plugwas field tested in 14 wells in Alaska in the lasthalf of 1989 and waa successfully located and Presently the through-tubing system is limited to2-1/8-in. OD equipment set in 7-5J8-in. OD casingplaced in 11 of those wells (Table 2). The purposes and 3-in. OD equipment in casing sizes up to

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    OTC 6459 LUIS E. Mendez, Martin P. Coronado and Danny J. Holder 59-5/8-in. (244,6mm). Further development wilIallow for smaller OD plugs with greater expansionattributes to set in larger casing. The systemwill also be enhanced for operation in higher tem-peratures. As more is learned about the nature ofthis system, effort will be directed to optimizingthe conveyance and utilization of power downhole,improving pump output. This will allow higher in-flation pressure resulting in increased pressure-holding capability of the plug.The system has been proved in oil and waterwellbores. Future development will involve adapt-ing this systentto work in harsher environments,such as drilling mud.CONCLUSION~A through-tubing wireline bridge plug system hasbeen developed and field tested in Prudhoe Bay,Alaska. The plug has been used for acidizing,fracturing, squeeze cementing, and water shut-offs.The system has been successfully field proven andis a viable method for setting a bridge plugthrough tubing. Through-tubing workover operationscan be accomplished in as few as two days, a dra-matic contrast in comparison to conventional

    workover methods. Moreover, the system does notrequire killing the well and risking formationdamage in order to set the plug.ACKNOWLEDGEMENTSThe authors gratefully acknowledge contributionsmade by the Prudboe Bay Unit Operators during fieldtesting and development of this tool and non-rigworkover technique. The views and conclusions ex-pressed in this paper do not necessarily implyagreement with Prudhoe Bay Operators or other PBUWorking Interest Owners. The authors also thankBaker Service Tools fo~ the opportunity to publishthis paper and Robin Robinson, Mark Plante, ShawnMcCarty, Frank Richardson, Jim Belew, Joe Klumpyan,Bill Berryman and Peggy Tucker for their valuablecontributions in preparing this paper.REFERENCE

    1. Walsh, M. D. and Holder, D. J.: InflatablePackers: Production Applications, paper SPE17443 presented at the SPE California RegionalMeeting, Long Beach, California, March 23-25,1988.

    2. Ibid.

    TABLE 1BRIDGE PLUG SPECIFICATIONSOutside diameter 4.19 in. 3.38 in, 3.0 in.

    106.4 mm 85.8 mm2.13 in.

    76.2 mm 54.1 mmInside diameter 1.25 in, 1,25 in. 0.63 in.31.7 mm 31.7mm 0.63 in,16.0 mm 16.0 mmMax. casing OD 9,63 in. 7,0 in. 9.63 in. 7.0 in. 9.63 in. 7.63 in.10 set elemenl 244.6 mm !77.8 mm 244,6 mm 177.6 mm 244.6 mm 193.8 mmMax. differential 16CHIpSi 250U psi 12CQpsi 3,000 psi 1500 psi 1500 psiacross element 12,409 kPa 17,235 kPa 8273 kPa 20,664 kPa 10,341 kPa 10,341 kPa

    Max. Temperature @ 250F 260F 225F 260F 225F 260Fmax. expansion 121C 136C lo7c 136C lo7c 136CMin. restriction for 4,31 in. 3,56 in, 3,72 in. 2.197 in,system to pass 109,4 mm 90,4 mm 79.2 mm 55.8 mm

    TABLE 2RECORD OFFIELD TESTINGWell Reason for Plug casing Tubing Well Well smallestNo. Date aridge Plug Size Size size Angfe Temp. Restsiclicmx-3 7-28 Acldlze 3.3/8 7 5-1/2 3s0 1s0 4.455D-7 7.31 Ac idize 3-3/ 8 7 5-1/ 2 35 210 3.725A-5 S lo,ll Frac 3 7 4.1/ 2 54 202 3.725A.19 S12 Frac 3 7 4.1/ 2 30 1s0 3.725N.3 9.10 Ac idize 3.3/ s 7 4.1/ 2 35 203 3,725X-15 9.10 Frac 3 7 5.1/ 2 35 Zfsl 3,725R1 9-13,15,18,20 Shul.Off 34J8 7 51/ 2 35 1so 4,455N-10 9.24 Shutoff 3318 7 5.1/ 2 220 180 3.72517-13 10.5 Shutoff 3.3s 7 4.1/2 47 1s0 3,725J-7 10.25,26 Squeeze 3.3/ s 7 7 40 22s N.A.H-14 11-18 Squeeze 33/ 8 7 5.112 47 200 3,725Q.3 12-01 Ac ldlze 3 7 5.t/ 2 32 180 3,72512-20 12.28,29 Shut-Off 3.3/ 8 7 5.1/2 22 1s5 3,725

    13.27 12.17 Frac 3.3/ 8 r 4.1/ 2 250 200 3.725

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    THRU TUBING ELECTRIC WIRELINESET BRIDGE PLUG SYSTEMWIRELINE

    CABLE HEAD

    COLLAR LOCATER

    COMPENSATINGPISTON SECTION

    MOTOR SECTION

    PUMP SECTION

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    HYDRAULICDISCONNECT

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    OPERl I 10NIL SETUP FORTHRU TUBING

    ELECTRC MIRELNE SSTBR OGE PLUG SYSTEN

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    SURIZING DISCONNECTED>LU FFIOMPLUG

    s 8

    SET PLUGm9.aE

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    TOOL OPERATIONFIGURE 3

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