User Manual S-Box
Contents
1. 3 Phue Unit 17 Denmore Industrial Estate Denmore Road Bridge of Don Aberdeen AB23 8JW User Manual S Box This Manual Covers the Following Part Numbers 100 3602 HVO OPS 3602 Rev A User Manual 4 Phuel T OIL TOOLS Table of Contents ROSVISION ISI EE ii A il NE e tee Ulea Ez 1 BS CA E E E 1 1 2 Product Identification 1 1 3 Declaration of Conformity occccccccccccnnccccnnnoconnnonnnnnnnnnnnonnnncnnncnnnnncnnss 2 2 Technical Specification ranas iii 4 3 LECMNICAl DESCTIDION mesias 5 3 1 Sheave Wheel and Bracket 5 SP EE rre ln Leder 5 CG NOW Die CC D 34 NPT PONT IGM A Oe NR E oT oT 6 4 Operation 7 41 Seting A 7 4 2 Packing Stick Tttmgireplacement 7 BO 10 e e ae ae E 9 O A PR eoe e e AEE bu do edad eate e 9 A 9 SEI CSI estepario epidural 10 c ROGO mmm 10 5 2 Gchedule sn 10 o3 020 0m 10 o TOO ae ane ee a 11 5 5 Redress Procedure 11 5 6 Maintenance Record Sheet 13 SR Tee e PU cr cm nn 14 7 Parts List and Drawings nennen 15 SZ 18 Table 1 Technical Dala se een ee ee rene 4 Table 2 Maintenance Record 13 Table 3 Parts List 100 3602 HV0 enne 15 Table 4 Redress Kit Part No RDK 3602 HVO esses 18 Table 5 Check Valve Redress Kit Part No RDK 2040 HV1 18 Table 6 Sheave Wheel Redress Kit RDK 2040 HNO 18 Table Suppor Ge ll E 19 Figure 1 Stu2. be located in the first instance to ensure that the manual issued refers to the correct equipment CEE 112G c T4 Phuel Oil Tools Ltd Unit 17 Denmore Industrial Estate Denmore Road Bridge of Don Aberdeen AB23 8JW Slickline Stuffing Box 2010 Model 100 3602 HVO Notified Body Reference 0359 O O This equipment meets with the requirements of the Machinery Directive and the Equipment and Protective Systems Intended for Use in Potentially Explosive Atmospheres Directive ATEX and has the label above affixed to it OPS 3602 Rev A 1 User Manual 4 Phuel 2 BOX OIL TOOLS 1 3 Declaration of Conformity DECLARATION OF CONFORMITY Phuel Oil Tools Limited hereby declare that the following equipment Model 100 3602 HVO Slickline Stuffing Box Also described as A mechanical device used for guiding Slicklines Wire lines into well bores while containing well bore pressure excluded from the Pressure Equipment Directive by virtue of Annex A 6 and 9 and is manufactured to achieve the following specification 15 NPT Maximum Working Pressure 10 000 Psi Test Pressure 15 000 Psi Maximum Line pull 2800 lbs 1270 Kg Service H2S Working Temperature Range 18 C to 121 C Total Weight 122 5 lbs 55 56Kg Overall Length A 40 1 02M Make Up Length B 39 0 99M Hydraulic Connection Yo NPT Was found to be in accordance with The European Machinery Directive 98 37 EC being implemented in the United King
3. age e Ensure threads are clean e Ensure thread protectors are fitted OPS 3602 Rev A 9 User Manual 4 Phuel T OIL TOOLS 5 Maintenance All maintenance to be carried out by suitably qualified and competent personnel 5 1 Introduction Regular maintenance of the equipment using Phuel redress kits or Phuel approved parts is essential to its continued safe operation Ensure that the pre and post job operating procedures are followed and that maintenance records are kept 5 2 Schedule The maintenance schedule may be governed by international or company standards and the following is considered to be the minimum requirements 5 2 1 Pre amp Post Job Hefer to Section 4 3 and Section 4 5 for details 5 2 2 Yearly e Disassemble Stuffing Box see 5 5 1 clean and degrease all components e Inspect the condition of all sealing surfaces and surface coatings e Re coat threads and sealing surfaces if necessary If in doubt contact Phuel Oil Tools Ltd e Replace all elastomeric seals with items from redress kit see spares Table 4 e Hegrease components e He assemble see 5 5 2 e Pressure test to maximum working pressure in accordance to testing procedure see 6 e Inspect paint work and repair as necessary 5 2 3 Five Yearly e Yearly Maintenance plus the following e Carry out 100 surface NDE on all surfaces e Pressure test to test pressure witnessed by verifying body 5 3 Safety e Many of the components a
4. dividual Items Individual items may be ordered as required using the part number specified Note O Rings conform to industry standards and may be substituted with those from other suppliers at the sole risk of the user OPS 3602 Rev A 18 User Manual Phuel S Box OIL TOOLS 8 1 2 Support Equipment The following support equipment is available on order from Phuel Oil Tools PatNo Qy Description 900 2042 STL Test Blank Table 7 Support Equipment OPS 3602 Rev A 19
5. do IY IV TT LTR FFP Geet eae CL AM Y iO A 30 8 ES lt ATTACH ID LABEL HERE Oy 22 In CNA Led EVE DD Q S O Go o Figure 5 Stuffing Box Body Assembly OPS 3602 Rev A User Manual S Box E E E Figure 6 Stuffing Box Wheel Assembly OPS 3602 Rev A 17 User Manual Phuel S Box OIL TOOLS 8 Spares Use only spares supplied or approved by Phuel Oil Tools Ltd It is recommended that sufficient quantities of the following spares be maintained to ensure that the equipment is always available when required Elastomeric spares are supplied in HNBR material as standard Many other materials are available please specify when ordering Se 1997 H80 Dam AAA T SEAL 754 DIA 802 1 998 H80 1 PISTON T SEAL 1 750 DIA 802 1 999 H80 1 PISTON T SEAL 750 DIA 801 0232 V90 1 O Ring B S Size 232 801 01 14 V80 1 O Ring B S Size 114 801 01 13 V90 1 O Ring B S Size 113 801 0348 V90 2 O Ring B S Size 348 Table 4 Redress Kit Part No RDK 3602 HVO Ce 1979 B21 emn cur een 31 NUT 100 1988 B21 1 BOP RETAINER 100 1980 B21 1 BOP SEAT 100 1985 PU9 1 BLOW OUT PLUG 801 0114 V80 1 O Ring B S Size 114 801 01 13 V80 1 O Ring B S Size 113 1100 2211 316 1 IBALL BEARING 0 250 DIA Table 5 Check Valve Redress Kit Part No RDK 2040 HV1 Part Number__ Quantity 100 2207 STL 1 ROLLER BEARING 213 08 EITVPB C3 Table 6 Sheave Wheel Redress Kit RDK 2040 HNO 8 1 1 In
6. dom by the Supply of Machinery Safety Regulations 1992 and as amended by S l 1992 3073 S I 1994 2063 and SI 2005 831 And the The European Directive on Equipment and Protective Systems Intended for Use in Potentially Explosive Atmospheres 94 9 EC being implemented in the United Kingdom by The Equipment and Protective Systems Intended for Use in Potentially Explosive Atmospheres Regulations 1996 SI 1996 192 and as amended by The Equipment and Protective Systems Intended for Use in Potentially Explosive Atmospheres Amendment Regulations 2001 SI 2001 No 3766 OPS 3602 Rev A 2 User Manual 4 Phuel S Box OIL TOOLS DECLARATION OF CONFORMITY This equipment was designed to meet with the following European Harmonised Standards BS EN ISO 12100 Part 1 Safety of Machinery Basic concepts general principles for design BS EN ISO 12100 Part 2 Safety of Machinery Technical principles BS EN 13463 Part 1 Non electrical Equipment Intended for Use in Potentially Explosive Atmospheres Basic Method and Requirements BS EN 13463 Part 5 Non electrical equipment intended for use in potentially explosive atmospheres Protection by constructional safety c BS EN 982 Safety of Machinery Safety Requirements for Fluid Power Systems and Their Components Hydraulics BS EN 1050 Safety of Machinery Principles for Risk Assessment This equipment has been classified as suitable for use within a potentially explosive atmospher
7. e achieved by simply pumping out the packing stick using the piston and with the snap on capability can be quickly replaced and drawn back in when the pressure is bled off 3 3 Blow out plug The blow out plug is incorporated so that in the event of a break occurring in the slickline the valve will automatically seal containing the well pressure OPS 3602 Rev A 5 User Manual Phuel S Box OIL TOOLS 3 4 NPT Port Identification NS 7 LS CZ Pal er Injection Port ZL E PLIES DS GPS Oe EPL EEE V TS ot Figure 4 NPT Port Identification The two ie NPT ports on the Stuffing box allow for the piston to be pressured and for chemical injection The ports are identified by hard stamping on the housing but if this is difficult to make out then the ports are arranged so that there is a difference in height between the two with the lower port being for Chemical Injection If the user is unable to determine the difference in the height then the ports can be identified visually by looking into the actual port and confirming the layout with the diagram above OPS 3602 Rev A 6 User Manual 4 Phuel S Box OIL TOOLS 4 Operation All operations to be carried out by suitably qualified and competent personnel 4 1 Setting Up Check that the Sheave can freely rotate and that there is no obvious bearing damage Do not use the Sheave unless it freely rotates Withdraw and lock the knurled plungers in th
8. e as follows CE 9 112G c T4 In addition to compliance with the aforementioned European Standards this equipment meets the requirements of the following internationally recognised standards API 6A hereby declare that the equipment described in this document has been designed and manufactured in compliance with the relevant sections and essential health and safety requirements of the aforementioned Standards Codes and Directives Regulations Name Colin McCracken Position Managing Director 10 May 2010 OPS 3602 Rev A 3 User Manual 3 Phuel S Box OIL TOOLS 2 Technical Specification Part Number 100 3602 HVO Connections 6 2 4 Acme 1 2 NPT Maximum Working Pressure 10 000 Psi 15 000 Psi Maximum Line Pull 3920 lbs 1782 Kg 40 1 02M 39 0 99M Ve NPT Table 1 Technical Data Figure 2 Technical Specification OPS 3602 Rev A 4 User Manual 3 Phuel S Box OIL TOOLS 3 Technical Description 3 1 Sheave Wheel and Bracket The bracket is made up of a lightweight casting containing the solid lightweight wheel and a quick release plunger arrangement to allow quick fitting or changing of the slickline The wheel assembly can also be separated from the stuffing box assembly allowing easier handling Quick Release Plungers Figure 3 Wheel assembly 3 2 Packing Stick The Phuel one piece packing stick assembly allows for the quick change of the packing stick This can b
9. e open position Lay the slickline on the sheave wheel and lock the plungers back in position Feed the slickline through the wire bush and the Spacer down through the stuffing box until it emerges from the base The Spacer selected should suit the working pressure requirements the steel one Is for high pressures and the brass one for lower pressure 6 500 psi max and has lower friction 4 2 Packing Stick fitting replacement lt is recommended to remove the Collar and Seal Housing from the Housing and fit those parts to the top of the lubricator This reduces the handling weight and eases the assembly procedure Place the Housing in a vice Remove the check valve assembly by unscrewing the Check Nut from the Housing Pump out the piston so that the Piston Plug is visible De burr the end of the wire and pass it through the Wire Bush Top Cap and Spacer and then through the Piston plug until it appears at the opposite side of the Housing The Top Cap should be made up to the Housing to prevent damage to the wire Disassemble the check valve assembly so that the wire can be pushed through There is no need to remove the BOP Seat just make sure that the ball is fitted and is pushed to the side to allow the wire to pass through Slide the Blow Out Plug onto the wire and push inside the Check Nut so that it sits just at the entry of the bore of the Check BOP SEAT Nut do not push the thin fin fully aam OUT PLUG inside Slide t
10. he BOP Retainer over the wire and make it up to the BOP RETAINER heck Nut Ech Check Nut Now make the check nut assembly back up to the Housing taking care OPS 3602 Rev A 7 User Manual 4 Phuel S Box OIL TOOLS not to bend the wire e The rope socket can now be assembled to the wire With no packing yet fitted it will be easier to manage the wire and avoid any damage e When ready to install the tool string into the lubricator firstly push the upper section of the tool string weight bars and jars through the Seal Housing that was fitted earlier Step 1 Place the S Box assembly on the deck at a suitable distance to avoid bending the wire and make up the rope socket to the top of the tool string Since there is no packing fitted yet the tool string should be pushed to near the bottom of the lubricator section to make it easier to pull through and make up the tool String It is recommended that a length of string be attached to the bottom of the tool string so that it can be pulled through if necessary as the initial friction of the S Box may appear higher than conventional Stuffing boxes e Now make up the S Box assembly to the Seal Housing e When ready to fit the packing remove the Top Cap and pump the piston out e Fit the two halves of the split packing together and ensure that the pegs and holes are engaged Follow the picture sequence overleaf to make up the packing s e Ensure that the Top Cap is tig
11. htened up fully A wrench will be required for this hand tight is not sufficient to allow the packing s to take the shape of the housing and to seal on the wire e The bracket assembly can now be fitted and the two set screws used to secure it in place e The wire is now ready to be clamped to the riser and the job can continue as normal QA CAP IDENT ES na BUSH cr SPACER SPLIT PACKING PACKING HOUSING OPS 3602 Rev A 8 User Manual 33 Phuel S Box OIL TOOLS 4 3 Pre Job e Ensure thread protectors are fitted e Check maintenance record sheet and ensure the equipment has been maintained by competent personnel e Check all certification is in date e Confirm information band is fitted and correct e Ensure equipment is suitable for the maximum working pressures and services involved e Ensure visible O rings are seated correctly and there are no signs of damage e Ensure threads are clean e Inspect for signs of damage e Pressure test to maximum well pressure 4 4 During Job e The Operator must check the temperature of the bearing area of the sheave by hand if any unusual noise or operating conditions arise If it becomes intolerable to hold a bare hand on this area for 30 seconds the temperature is likely to be in excess of 65 C and operations should cease until an investigation into the source of the heat has been performed e Avoid excessive movement 4 5 Post Job e Inspect for signs of dam
12. ming BOX Sally EEN il Figure 2 Technical Specification seeeessesesseeesssseeeeeeenennenns 4 Figure 3 Wheel assembly esses ener nnns 5 Figure 4 NPT Port ldentinicatio eege 6 Figure 5 Stuffing Box Body Assembly 16 Figure 6 Stuffing Box Wheel Assembly nnnannnnnnnnennnnnnnnnnnnnnnnnnnnnennnnnnnnne 17 OPS 3602 Rev A User Manual A Phuel S Box OIL TOOLS Revision History Issue Release Date Rev A 20 July 10 Initial Issue OPS 3602 Rev A i User Manual 3 Phuel S Box OIL TOOLS Safety WARNING Trapped air requires considerable time to compress and when it is compressed is highly dangerous lt has enough stored energy to separate parts with considerable force All pressure equipment has a particular pressure rating and care must be taken to ensure that no item is used in a situation that may cause its working pressure to be exceeded All personnel involved in pressure testing must be formally trained competent and utilise the appropriate PPE Safe Lok devices should be checked for positional security to avoid unnecessary movement of the collar Ensure the identification band plate is fitted and is displaying the correct information as per the Tag Sheet Index This equipment and the equipment it is attached to is heavy never position yourself below a suspended load Caution There are potential entrapment points at the tangent point
13. move spring packing stick and piston from housing Split seal housing and housing Remove NPT plug check valve spring and check valve from housing Remove grease nipples from bearing shaft and bearing hub Remove and discard all O rings and T seals Degrease and clean all components OPS 3602 Rev A 11 User Manual 4 Phuel T 5 5 2 OIL TOOLS Re Assembly Prior to assembly all parts should be carefully cleaned inspected for any signs of damage and greased Note Hemove thread protection Fit O rings to the housing seal housing check nut and BOP seat Fit T seals to piston and packing housing Fit ball bearing BOP seat Bop plug and retainer to check nut Insert bearing into wheel centre Fit the wheel into the bracket using the bearing shaft bearing nut and split cotter pin Fit 1 8 NPT grease nipple to bearing shaft Ensure the Sheave Wheel is greased by backing off the bearing nut and pumping the grease then re tighten the bearing nut Failure to do this will stop any grease from entering the bearing Note Attach 3 knurled spring plungers to bracket Insert lee plug into housing and using pin punch tap in until seated Insert check valve seal check valve spring and NPT plug into housing Make up seal housing to housing and place collar over housing Fit dust seal to tapered bearing and place on housing Place bearing hub onto housing fit 2 tapered bearing and dust seal Fit lock nut and tighten i
14. n place Fit grease nipple to hub Ensure bearing hub is correctly orientated and the threaded hole on the locking nut aligns with the slot in the bearing hub Fit lock ring and spring plunger L handle to lock nut Fit packing stick to piston Insert piston and spring into the housing Insert packing housing into housing and tighten Fit wire bush and nordlock washer to top cap and fit to packing housing Fit BOP assembly to the base of the housing Attach wheel assembly to bearing hub and fit spring plunger L handle locking the assembly in place After reassembly item is to be tested in accordance with the test procedure Para 6 to maximum working pressure OPS 3602 Rev A 12 User Manual Phuel T 5 6 Maintenance Record Sheet Date Type of Performed Verified Comments Performed Maintenance By By LL ee eee LL LL LL IE eee NEN ten Table 2 Maintenance Record OPS 3602 Rev A 13 User Manual Phuel S Box OIL TOOLS 6 Testing All testing is to be carried out in the designated test area and by suitably qualified and competent personnel WARNING Trapped air requires considerable time to compress and when it is compressed is highly dangerous It has enough stored energy to separate parts with considerable force Fit appropriate test cap and blanks Fill with testing fluid bleeding off any air within the system Apply a pressure of 500 psi and ensure pressure holds for a minimum of 10 minutes Increase pre
15. re heavy and should not be lifted without lifting aids OPS 3602 Rev A 10 User Manual 4 Phuel S Box OIL TOOLS Ensure all pressure testing is carried out in the appropriate testing area by suitably qualified personnel Wear appropriate personal protective equipment Do not over exert yourself while using torque wrenches Use appropriate mechanical advantages when available Ensure that all tools and equipment are in good condition and are suitable for the intended use Clear up any fluid spills immediately to avoid slips 5 4 Tools The following tools are required Memac Chain Wrench No2 with 14 chain Other pipe wrenches may be used but will mark equipment 2 hex Allen key 3 8 hex Allen key 1 2 Spanner 3 4 Spanner Pin punch Hammer Wire Brush 5 5 Redress Procedure 9 9 1 Dis Assembly Unlock the spring plunger L handle and remove the wheel assembly from the bearing hub Remove split cotter pin bearing nut and bearing shaft from wheel assembly Remove wheel and knurled spring plungers from bracket Remove BOP assembly from base of housing Remove retainer BOP plug BOP seat and ball bearing from check nut Remove top cap Remove washer and wire bush from top cap Loosen packing housing and remove Remove spring plunger L handle from lock nut Loosen and remove lock ring and lock nut Remove tapered bearing bearing hub and 2 tapered bearing and associated dust seals from housing Re
16. s between the Slickline and the Sheave All personnel must be warned to stay clear of these areas The Sheave Wheel is detachable to allow easier handling Figure 1 Stuffing Box Safety OPS 3602 Rev A lil User Manual 4 Phuel S Box OIL TOOLS 1 Introduction 1 1 General The Phuel S Box introduces a truly innovative feature that ensures that Slickline packing can be easily and consistently redressed The S Box is made up in three sections to facilitate manual handling and to allow the tool string to be fed through the top of the riser before make up This user manual serves as an introduction to the equipment and contains specifications operational planning and maintenance instructions parts list and drawings 1 2 Product Identification Phuel products are identified by a unique serial number that provides full product traceability Each product is supplied with a documentation pack that contains product certification and material inspection reports The serial number is always etched on the surface of the product but can sometimes be difficult to find or read after painting A customer identification number is also included to allow the customer to track the asset in their system A stainless steel band secures a nameplate tag that is stamped with the information shown below PHUEL OIL TOOLS LTD DESCRIPTION amp SIZE CUSTOMER ID No PHUEL ID No 06 XXX XX MWP amp SERVICE TEST DATE This tag should
17. ssure to 10 000 psi Maximum Working Pressure allow to stabilise and maintain this pressure until it is evident there are no apparent leaks Testing to be carried out to Test pressure when decreed by maintenance schedule Bleed off pressure drain test fluid and dry Remove test caps Apply coating of de watering solution to protect the bore and threads Fit thread protectors On completion of all maintenance ensure the maintenance record sheet 5 6 is completed OPS 3602 Rev A 14 User Manual 7 Phuel T OIL TOOLS 7 Parts List and Drawings Item Part Number Qty 100 1974 480 HOUSING SEAL HOUSING 6 1 2 4 SOLID COLLAR 6 1 2 4 6 100 1977 B21 PISTON 8 100 1981 316 LOCKRING_________________zzz_ 9 100 2526 B21 WIREBUSH III PISTON T SEAL 1 750 DIA PISTON T SEAL 750 DIA COMP SPRING C551 1230 TAPERED ROLLER BEARING 32012XA SPACER FOR 10 000 PSI WP STEEL 100 3222 B21 SPACER FOR 6 500 PSI WP BRASS INNER SPRING RIGHT HAND 45 SCU 0587 3A4 Set Screw Cup Point 1 2 UNC x 125 Long 2 Table 3 Parts List 100 3602 HVO NO OPS 3602 Rev A 15 User Manual 33 Phuel S Box Es o D ss 2X 1 2 NPT en 36 en 2 6 1 2 4 ACME e lee NY NESS E MS Y el A d OONVKNAVAAY ES N27 H LX G ADA E A Y gt gt NG E NN NN EE ERr oN RSS AA A AT L RLL L LLR L ha PT LLL LELEI TELLS LETT IRO Fe CS DEC o 00009 77 A ES SCH ZA SDE ES CN fon
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