TECH MANUAL

TECH-4.06 10K DSU4 O/U S/P

4.06”, 10,000 PSI WORKING PRESSURE, DSU

SERIES, OVER/UNDER STRIPPER PACKER
W/ CB44 BOTTOM CONNECTION

RIG/PLANT REFERENCE REFERENCE DESCRIPTION

ADDITIONAL CODE SDRL CODE TOTAL PGS

This document contains proprietary and confidential information TEXAS OIL TOOLS
which belongs to National-Oilwell Varco, L.P., its affiliates or
subsidiaries (all collectively referred to hereinafter as "NOV"). It is 3770 Pollock Dr.
REMARKS
loaned for limited purposes only and remains the property of NOV. Conroe, TX 77303
Reproduction, in whole or in part, or use of this design or Phone 936-777-6100
distribution of this information to others is not permitted without the
MAIN TAG NUMBER DISCIPLINE
express written consent of NOV. This document is to be returned to Fax 936-756-8102
NOV upon request and in any event upon completion of the use for
which it was loaned. This document and the information contained
CLIENT PO NUMBER and represented herein is the copyrighted property of NOV.
 National Oilwell Varco
CLIENT DOCUMENT NUMBER DOCUMENT NUMBER REV

Client Document Number M60DSU4-0445XB-MAN-001 02

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REVISION HISTORY

02 17/Dec/2013 Revision CP KM MW
01 08/May/2013 Initial Release CP KM MW
Rev Date (dd.mm.yyyy) Reason for issue Prepared Checker Approved

CHANGE DESCRIPTION

Revision Change Description

01 Initial Release
02 Add Lower Rotation Functionality Reference in Section 1

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TABLE OF CONTENTS

1.0 INTRODUCTION

2.0 FEATURES

3.0 CERTIFICATION/SERVICE

4.0 OPERATION

5.0 MAINTENANCE

6.0 SPECIFICATIONS

7.0 M60DSU4-0445XB
4.06 10K OVER UNDER STRIPPER PACKER
Reference Drawing M60DSU4-0445XB-ART-001 & M60DSU4-0445XB-ART-002

*DSU4-SK01*
SEAL KIT F/ 4.06 10K OVER UNDER STRIPPER PACKER
Reference Drawing M60DSU4-0445XB-ART-001

DSU4-CK**
CONVERSION KIT
Reference Drawing M60DSU4-0445XB-ART-001

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M60DSU4-0445XB
4.06 10K DSU4 OVER UNDER STRIPPER PACKER
Reference Drawings M60DSU4-0445XB-ART-001 & M60DSU4-0445XB-ART-002

1.0 FEATURES

The Texas Oil Tools DSU4 Over/Under Stripper Packer is designed to pack-off on coiled tubing as
it is stripped in and out of the well, at working pressures up to 10,000 psi. This design provides two
independent hydraulically actuated packers within the same body. This unique feature allows the
operator to utilize one packer while the other is held in reserve; when first packer is unable to effect
a seal, the second packer is actuated. This ability effectively doubles the time between packer
changes. Changing packers is always easier, but it is particularly advantageous when changing
packers with tubing in the well. Note: 4.06” bore extends only to bottom of lower bushing.

If DSU4 Stripper Packer is equipt with lower rotation functionality, reference Tech Manual
M60BV46-2463-MAN-001.

2.0 SERVICE

H2S SERVICE - All well fluid wetted alloy components to NACE MR 01 75, with Viton and Poly Myte
seals. Hydraulic seals are Nitrile. Operating temperature range 20ºF. to +200ºF. Note: seals and
pack off elements are available for higher temperatures.

NORTH SEA SERVICE - In addition to the NACE Specification s and API requirements additional
Charpy Impact and NDE are carried out. A Design Review and Certificate of Compliance by DNV,
Lloyds, or Bureau Veritas are furnished with the Data Book.

ARCTIC 50ºF H2S SERVICE - All well fluid wetted alloy components to NACE MR 01 75, with low
temperature o rings and special Poly Myte seals. Charpy Impact Tests at 50ºF and NDE on all
parts required by API 6A. Operating temperature range 50ºF. to +200ºF.

3.0 PACKERS - Reference Drawing M60DSU4-0443XB-ART-001

PREMATURE PACKER WEAR - The internal wear bushings above the packers are extra-long, for
better centering of the coiled tubing and longer wear life. The single most frequent cause of
premature packer wear or failure, is worn bushings. At very low well and hydraulic pressures, worn
bushings may be useable. At higher pressures, it is essential that the non-extrusion rings and
packer bushings fit closely around the tubing to prevent packer extrusion. Bushings must be
replaced frequently to minimize any extrusion gaps.

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4.0 OPERATION

PACKERS - Reference Drawing M60DSU4-0445XB-ART-001

PREMATURE PACKER WEAR - The internal wear bushings above the packers are extra-long, for
better centering of the coiled tubing and longer wear life. The single most frequent cause of
premature packer wear or failure, is worn bushings. At very low well and hydraulic pressures, worn
bushings may be useable. At higher pressures, it is essential that the non-extrusion rings and
packer bushings fit closely around the tubing to prevent packer extrusion. Bushings must be
replaced frequently to minimize any extrusion gaps.

PACKER REPLACEMENT

Lower Packer - Close BOP pipe rams to control well pressure and vent residual well pressure that
may remain between the stripper and the BOP. Back out the two lock screws and open wide both
doors (15). Pressure up "PRIMARY RETRACT" port and fully retract piston (3). Pressure up
"WINDOW OPEN" port and fully open window exposing packer elements and seal (1-2). Remove
non-extrusion ring (2-5) and energizer (26). Support bushing (2-2) and remove packer interlock (2-
6); remove bushings (2-2) & (2-1). Inspect all bushings, packer elements and seals. Replace as
necessary.

Install bushing (2-1) & seal (1-2). Install and support bushing (2-2); install packer interlock (2-6),
energizer (26) & non-extrusion ring (2-5). Pressure up "WINDOW CLOSE" port and fully close
window. Close doors (15); turn lock screws in until extended behind connector studs (11).

Upper Packer - Close BOP pipe rams to control well pressure and vent residual well pressure that
may remain between the stripper packer and the BOP. Pressure up "SECONDARY RETRACT"
port and fully retract piston (4). Rotate split cap (13) to most advantageous position and remove
socket head cap screws (18). Install into threaded holes in split cap (13) as a tool to facilitate
removal. CAUTION: split cap weighs approx. 45 lbs. Grasp cap screw (18) and separate split cap
(13) exposing bushing (2-4). Remove bushing (2-4). Pressure up "SECONDARY PACKOFF" to
push packing elements up. Remove non-extrusion ring (2-5), energizer (26), and packer interlock
(2-6). Remove bushing (2-3). Inspect all bushings and packer elements; replace as necessary.

Install bushing (2-3). Pressure up "SECONDARY RETRACT" port and fully retract piston (4).
Install packer interlock (2-6), energizer (26) and non-extrusion ring (2-5). Install bushing (2-3);
install split cap (13). Install socket head cap screws (18) and bolt two halves of split cap (13)
together.

CAUTION: When pressurizing, CLOSE WINDOW port. Ensure OPEN WINDOW port is vented,
as an overpressure condition can occur, causing Seal failure.

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5.0 SUGGESTED MAINTENANCE SCHEDULE

After Every Job - Remove the packer and inspect all accessible seals. Remove all trace of well
fluids.
Once A Month - Remove the packers and bushings. Thoroughly clean all of the items. Grease and
assemble to proper technical manual.
Once A Year - Disassemble completely and replace all of the seals.

Two Year NDE Requirements - All parts exposed to the well fluids will have to be inspected by
NDE methods. The preferred NDE test would be a wet magnetic particle testing. Not all parts can
be tested in this method. If the parts cannot be inspected with MPI then a dye penetrant test will
have to be conducted.
Four Year NDE Requirements - All parts exposed to the well fluids, loaded by well pressure or
pressure containing will have to be inspected by NDE methods. The preferred NDE test would be a
wet magnetic particle testing. Not all parts can be tested in this method. If the parts cannot be
inspected with MPI then a dye penetrant test will have to be conducted.
Field Inspections of TOT Stripper Packers - Begin by disassembling the stripper packer. Refer to
the proper technical manual for the detailed instructions for disassembly. Clean all of the parts
either with a steam washer, solvents, or other means. All of the dirt, rust, and scale must be
removed.
Worn out packers and bushings are the main reason a stripper will leak. Examination of the packers
and bushing after each job is critical. The packer should be replaced after every job. Corrosion is
another cause for the stripper packer to leak. How much corrosion is too much? Any corrosion that
causes pitting in the base material is too much. The pitting will directly affect the sealing capabilities
of the well bore seal, o-rings, and polypak seals.
Critical areas that must be examined include the well bore seal groove and sealing area. The upper
bushing stack and bushing sleeve is susceptible to corrosion. The bushings themselves will not
corrode but the fluids get trapped between the bushings and the housing and tend to act as a
catalyst for corrosion.
The Following Is an Individual Part Detail of What to Look out for During Inspections.
Bushings - The critical bushings are those just above and just below the packer, the ones that
prevent the packer from extruding. If these bushings are allowed to wear too much it will create a
leak path for the packer. Replace the bushings if they become worn. Worn is defined as wear that
can be measured with a caliper to be .10” larger than the coiled tubing size (i.e for 1.25 coiled
tubing, 1.350 would be classified as worn).
Bushing Stack - The bushings at the upper end of the stripper packer are guide bushings and the
main function is to guide the coiled tubing and prevent it from buckling between the chains and the
packer. The top one will normally wear out faster than the others. It is important that you check the
wear on these frequently.

Well Bore Seal Grooves - The items that house the well bore seals is critical. Damaged seals and
corrosion are the most common cause for this item to leak.

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6.0 SPECIFICATIONS
Reference Drawings M60DSU4-0445XB-ART-001 M60DSU4-0445XB-ART-002

Working Pressure

DSU4…………………………………………………………………………………..10,000 psi
Weight (approx.)………………………………………………………………………..1375 lbs.

Hydraulic Pressure

Pack-Off………………………………………………………………………………...3,000 psi
Retract…………………………………………………………………………………..3,000 psi

Hydraulic Pressure to Operate Window (Max)

Open…………………………………………………………………………………….3,000 psi
Close…………………………………………………………………………………….3,000 psi

Hydraulic Volume to Actuate Window

Close………………………………………………………………………………………188 in3
Open………………………………………………………………………………………...41 in3

Hydraulic Volumes to Actuate the Piston

Primary Pack-Off…………………………………………………………………………..27 in3

Primary Retract…………………………………………………………………………….27 in3
Secondary Pack-Off……………………………………………………………………….28 in3
Secondary Retract…………………………………………………………………………28 in3

Torque

Nut (19)………………………………………………………………………………….300 ft. lbs.

Flat Head Cap Screws (23)…………………………………………………………….20 ft. lbs.
Hex Head Cap Screws (24)………………………………………………………........50 ft. lbs.

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7.0 M60DSU4-0445XB
4.06 10K OVER UNDER STRIPPER PACKER
Reference Drawing M60DSU4-0445XB-ART-001

Disassembly - Repeat disassembly portion of packer replacement procedure as described

previously. Unscrew lock hub (14) from the upper body (8). Remove seals (1-3 & 1-4) and O-ring
(1-1). Using hydraulic hand pump, cautiously pressurize the "SECONDARY PACKOFF" port to
push piston (4) up and remove. Remove T-seal (1-5) and seals (1-3 & 1-4).

Remove cap nuts (19), taking care that doors (15) do not fall. Separate upper body (8) from lower
body (10). Remove six flat head hex socket cap screws (23), window stop (7) and, if necessary,
two #2 SAE plugs (20).

Using hydraulic hand pump, pressure up "WINDOW CLOSE" port to push packer change cylinder
(5) up, taking care not to damage the sealing surface. Unscrew cylinder stop (6) from cylinder (5).

Release pressure from "WINDOW CLOSE" port. Remove twelve socket head cap screws (24),
window guide (9) and seal (1-6). Remove packer change cylinder (5), seals (1-6 & 1-8) and O-ring
(1-7). Unscrew lower sub (12) from lower body (10); Remove seals (1-3 & 1-4) and T-Seal (1-9)
Taking care not to damage sealing surfaces, remove piston (3) and T-Seal (1-5). Remove seal (1-
3) from lower body (10).

Clean and inspect all parts for wear and damage. Lubricate and replace as necessary.

Assembly - Reverse above Disassembly Procedure in same sequence and complete second
portion of Packer Replacement Procedure.

M60DSU4-0445XB
4.06 10K OVER UNDER STRIPPER PACKER
Reference Drawing M60DSU4-0445XB-ART-001

H2S, NORTH SEA &

ITEM QTY DESCRIPTION
ARCTIC SERVICE
1 *DSU4-SK01* 1 SEAL KIT DSU4
2 DSU4-CK** 1 CONVERSION KIT
3 2000-3401B 1 LOWER PISTON
4 2000-3402B 1 UPPER PISTON
5 2000-3403B 1 CHANGE CYLINDER
6 2000-3404 1 STOP CYLINDER
7 2000-3405 1 STOP WINDOW
8 2000-3406B 1 UPPER BODY
9 2000-3407B 1 GUIDE WINDOW
10 2000-3408B 1 LOWER BODY

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11 2000-3409B 4 STUD
12 2000-3419B 1 LOWER SUB CB44
13 2000-3411B 1 SPLIT CAP
14 2000-3412B 1 LOCK HUB
15 M602008-5061 2 DOOR
16 2006-5062 2 THUMBSCREW
17 2000-3418 2 THRUST BEARING
18 7947-1212Y 2 SHCS .750-10UNC X 3.00
19 9705-1033B 4 NUT
20 7934-0202 2 PLUG SKT #2
21 7934-0204 1 PLUG SKT#5
22 7934-9094R 3 PLUG ASSEMBLY
23 7946-0505 6 SHCS .313-18UNC X 1.25
24 7935-1008X 12 HEX SCS .625-11UN X 2.00
25 8209-0446B 1 UNION NUT CB44
26 8412-3750 2 ENERGIZER
27 DSU6-RWK1 1 ANTI ROTATION
28 7912-2533 2 GREASE FITTING
29 P601000929 1 RELIEF VALVE
30 8007-2621B 1 LOCK COLLAR CB44
31 8002-0362 1 THREAD PROTECTOR
32 7813-A433 1 O-RING CB44
33 7992-1644 1 BACK-UP RING CB44

*DSU4-SK01*
SEAL KIT F/ 4.06 10K OVER UNDER STRIPPER PACKER
Reference Drawing M60DSU4-0443XB-ART-001

DSU6-SK01 DSU6-SK01B
ITEM QTY DESCRIPTION
H2S & NORTH SEA ARCTIC SERVICE
1-1 7813-3369 7813-A369 1 O-RING
1-2 7954-5509 7954-5509B 2 M-SEAL
1-3 7950-3433 7950-A433 5 T-SEAL
1-4 7821-55A2P 7821-55A2P 4 SEAL POLYMYTE
1-5 7951-3363 7951-A363 2 T-SEAL
1-6 7821-7752 7821-7752B 1 SEAL DEEP B
1-7 7813-3374 7813-A374 1 O-RING
1-8 7951-3444 7951-A444 1 T-SEAL
1-9 7813-3367 7813-A367 1 O-RING

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DSU4-CK***
CONVERSION KIT F/ SEAL KIT F/ 4.06 10K OVER UNDER STRIPPER PACKER
Reference Drawing M60DSU4-0443XB-ART-001

H2S & DNV-32°C &

ITEM DESCRIPTION QTY
ARCTIC -50°F SERVICE
CONVERSION KIT - 1.25 COILED TUBING DSU4-CK37
2-1 UPPER BUSHING 1 9705-1137
2-2 LOWER BUSHING 1 2000-9537
2-3 GUIDE BUSHING 1 2000-9637
2-4 TOP BUSHING 1 2000-9737
2-5 NON EXTRUSION RING 2 8412-2437
2-6 PACKER INTERLOCK 2 8412-6037
CONVERSION KIT - 1.50 COILED TUBING DSU4-CK41
2-1 UPPER BUSHING 1 9705-1141
2-2 LOWER BUSHING 1 2000-9541
2-3 GUIDE BUSHING 1 2000-9641
2-4 TOP BUSHING 1 2000-9741
2-5 NON EXTRUSION RING 2 8412-2441
2-6 PACKER INTERLOCK 2 8412-6041

CONVERSION KIT - 1.75 COILED TUBING DSU4-CK44

2-1 UPPER BUSHING 1 9705-1144
2-2 LOWER BUSHING 1 2000-9544
2-3 GUIDE BUSHING 1 2000-9644
2-4 TOP BUSHING 1 2000-9744
2-5 NON EXTRUSION RING 2 8412-2444
2-6 PACKER INTERLOCK 2 8412-6044
CONVERSION KIT - 2.00 COILED TUBING DSU4-CK51
2-1 UPPER BUSHING 1 9705-1151
2-2 LOWER BUSHING 1 2000-9551
2-3 GUIDE BUSHING 1 2000-9651
2-4 TOP BUSHING 1 2000-9751
2-5 NON EXTRUSION RING 2 8412-2451
2-6 PACKER INTERLOCK 2 8412-6051

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H2S & DNV-32°C &
ITEM DESCRIPTION QTY
ARCTIC -50°F SERVICE
CONVERSION KIT - 2.37 COILED TUBING DSU4-CK61
2-1 UPPER BUSHING 1 9705-1161
2-2 LOWER BUSHING 1 2000-9561
2-3 GUIDE BUSHING 1 2000-9661
2-4 TOP BUSHING 1 2000-9761
2-5 NON EXTRUSION RING 2 8412-2461
2-6 PACKER INTERLOCK 2 8412-6061
CONVERSION KIT - 2.87 COILED TUBING DSU4-CK73
2-1 UPPER BUSHING 1 9705-1173
2-2 LOWER BUSHING 1 2000-9573
2-3 GUIDE BUSHING 1 2000-9673
2-4 TOP BUSHING 1 2000-9773
2-5 NON EXTRUSION RING 2 8412-2473
2-6 PACKER INTERLOCK 2 8412-6073

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M60DSU4-0445XB-ART-001

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M60DSU4-0445XB-ART-002

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