User Manual Insitu Riser 5 1/8 ID 8 ¼ Box x 9
Contents
1. 1 Introduction 1 1 General The Phuel Riser or Lubricator is a pressure containing cylinder used when performing wireline operations Its purpose is to allow the wireline tool string to be raised above the wellhead valve allowing entry and exit from the well bore The Riser body is constructed in three pieces with a metal to metal ACME sealing connection backed by an o ring Risers up to 1 7m length have a 1 piece body The end connections are Otis type with the Phuel safe lok features incorporated as standard This user manual serves as an introduction to the equipment and contains the relevant specifications operation planning and maintenance instructions parts list and drawings 1 2 Product Identification Phuel products are identified by a unique serial number that facilitates 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 stainless steel band secures the nameplate tag that is stamped with the information shown This tag should be located in the first instance to ensure that this manual refers to the correct equipment A customer identification number is also included to allow the customer to track the asset in their system Phuel Oil Tools Ltd Description amp Size Customer ID No Phuel ID No M2. and rotate through 90 Lower the collar until it reaches the top of the threads Turn the collar anticlockwise until the start of the thread is found and then start turning clockwise to make up the collar to the box thread Tighten the collar down OPS 3954 Rev A User Manual Insitu Riser EL 3 1 3 Breaking the Safe Lok Collar Unscrew the collar completely Lift the collar up ensure the stop pins go through the gaps in the raised rim Rotate the collar 90 and lower gently so that the pins rest in the grooved portion of the raised rim The connection can now be separated without any risk of dropping the collar 3 2 Test Port Saver Sub User Manual Insitu Riser The saver sub provides the ability to change a damaged pressure fitting without repairing or replacing a major component The saver sub is held in place by two socket head cap screws and is sealed by means of an o ring The Saver sub can be replaced with a blank version to avoid the need to fit a pressure blanking plug that would otherwise protrude from Riser assembly 11 I m NPT Saver Sub Figure 3 NPT Saver Sub OPS 3954 Rev A User Manual Fn 3g Phuel Insitu Riser OIL TOOLS 3 3 Isolation Valve The isolation valve fitted into the Insitu Risers allows the connection of ancillary equipment such as gauges Use of the valve permits the system to be isolated as required for the equipment to be changed Figure 4 Isolati
3. Valve and Protector eennnnnnnnnnnvnnnnnnnnnnnnnnvnnnnennnnnnnnnnnennn 6 Figure 6 Insitu Riser Assembly Abbe 16 OPS 3954 Rev A i Phuel User Manual Insitu Riser Revision History Issue Release Date Description Rev A 23 Jun 11 Initial Issue OPS 3954 Rev A User Manual Ewe Insitu Riser OIL TOOLS Safety 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 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 utilising the appropriate PPE Safe Lok devices where used 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 Finger Glove and loose clothing trap area Care to be taken to avoid trapping fingers gloves and loose clothing during stabbing procedure Figure 1 Riser Safety OPS 3954 Rev A iii User Manual QU Phuel Insitu Riser
4. check that the pressure has been removed Grip the pressure fitting and pull out the saver sub with a pulling and rocking motion If the pressure fitting has been removed already then two 14 20 UNG screws not supplied can be used to jack out the sub Inspect the o ring for signs of damage and replace if necessary Inspect the seal bore for signs of damage and report if necessary If required remove the pressure fitting clean and inspect the pressure port To re fit the sub apply grease to the o ring and seal bore Push the sub into the bore by hand as far as possible ensuring that the part is centralised in the bore Fit the screws and washers and tighten to drive the o ring into the bore Make up each screw equally to ensure that the sub does not become twisted Fully tighten the screws 4 5 Replacing the Isolation Valve Assembly It is not expected that the saver sub would need to be replaced during normal operations but if damage occurs to a pressure fitting or a leak is found during pressure testing then this procedure should be followed Ensure that the pressure is bled off Remove any pressure fittings or gauges OPS 3954 Rev A 8 User Manual IQ Phuel Insitu Riser Remove the two socket head cap screws and washers from the protector and remove the protector Remove the two socket head cap screws and lock washers If they appear unusually tight or difficult to move re check that the pressure has been removed
5. 571 N66 FITTING PROTECTOR FOR 8 68 OD 1 9 110 2329 3A4 STOP PIN 4 10 801 0108 V90 O Ring B S Size 108 1 11 801 0119 V90 O Ring B S Size 119 1 12 801 0438 V90 O Ring B S Size 438 2 13 SHC 0583 3A4 Soc Hd Cap 1 2 UNC Length 3 4 in 6 14 WNL 0580 316 WASHER NORDLOCK M12 10 15 117 2166 STL CIRCLIP INTERNAL 18mm DHO 18 1 16 190 1758 416 AFO Plug PLAA3124010A 1 98 910 2756 N66 8 25 4 ACME FEMALE PROTECTOR 1 99 910 3369 N66 MALE PROTECTOR DW 9 4 ACME 1 Table 3 Insitu Riser Parts List Item Number Part Number Description Quantity 10 801 0108 V90 O Ring B S Size 108 1 11 801 0119 V90 O Ring B S Size 119 1 12 801 0438 V90 O Ring B S Size 438 2 Table 4 RDK 3954 HVO OPS 3954 Rev A 15 User Manual s Phuel Insitu Riser CIT DEER EE FJ DETAIL B DETAIL A Figure 5 Insitu Riser Assembly OPS 3954 Rev A 16 User Manual QU Phuel Insitu Riser 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 Viton material as standard Many other materials are available please specify when ordering 8 1 1 Individual 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 fr
6. Grip the isolation valve assembly and pull out using a pulling and rocking motion If the assembly is difficult to remove then two 14 20 UNC screws not supplied can be used to jack out the sub e Inspect the o ring for signs of damage and replace if necessary e Inspect the seal bore for signs of damage and report if necessary e Inspect the pressure port e Tore fit the assembly apply grease to the o ring and seal bore e Push the assembly into the bore by hand as far as possible ensuring that the part is centralised in the bore e Fit the screws and washers and tighten to drive the o ring into the bore Make up each screw equally to ensure that the assembly does not become twisted e Fully tighten the screws e Refit the protector 4 6 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 O ring is seated correctly and there are no signs of damage e Ensure threads are clean e Inspect for signs of damage e Pressure test to 1 2x the maximum well pressure e Carry out a collar lock test and ensure correct operation e Ensure all connections are tight and that the test port is tightly fitted 4 7 During Job Ensure collar is fully down Avoid excessi
7. Phu Unit 17 Denmore Industrial Estate Denmore Road Bridge of Don Aberdeen AB23 8JW User Manual Insitu Riser 5 1 8 ID 8 Box x 9 4 Pin 1 45m This Manual Covers the Following Part Numbers 110 3954 HVO OPS 3954 Rev A User Manual QU Phuel Insitu Riser Table of Contents Revision HIStory E EO UL TIT ii cq e M iii MES Me td M c 1 MET err 1 1 2 Product Identification Luse 1 2 Technical Specification EE 2 3 Technical Deseripti on ccr EE 3 SONNEN CITIES ILES ROTE 3 3 2 Test Port Saver Sub neret ener eee 5 3 38 Isolation SE 6 EEE EE EN CE 7 4 1 Buy M PET 7 4 2 Making Up the EE 7 4 3 Breaking the connechon een 7 4 4 Replacing the Saver Sub 8 4 5 Replacing the Isolation Valve Assembly sssssneneeesseessneessesrerrrnreeeses 8 25 PS OU ct 9 4T DUMME NOW EE 9 PRINS 9 er Nee 10 5 1 Introduction EE 10 52 EE 10 59 0 o ers 11 54 Redress Procedure Aass sii stipe ERR IR RE CE Re ERU maine 11 5 5 Maintenance Record heet 13 T MT vanen 14 7 Parts List and D NNA 15 GE e Pe 17 Table 1 Technical Data saved r pte neta cotes ta eto tud 2 Table 3 Maintenance e te E 13 Table 6 Insitu Riser Parts List eene ntn tens 15 Table 7 RDK 3954 HVO0 errnnnnnnronnnrnnnvnnnonnnnrnnnnnnrnnnnrnnnvnnnnnnnnnnnnnnnennnennnnennnnnn 15 Table 18 Supporting Equipment essere ere 17 Gel iii Fig re 2 E 2 Figure 3 NPT Saver SUD EE 5 Figure 4 Isolation
8. WP amp Service Test Date OPS 3954 Rev A 1 User Manual 33 Phuel Insitu Riser OIL TOOLS 2 Technical Specification Part No 110 3954 HVO Connections SQU Pin 64 Box Vo NPT Length A 60 74 1 54m Make up Length B 57 09 1 45m Weight 415lbs 188kgs Maximum Working Pressure 6 500 Psi Test Pressure 10 000 Psi Table 1 Technical Data A Figure 2 Riser OPS 3954 Rev A EL 3 Technical Description 3 1 Collar Safe Lok User Manual Insitu Riser The safe collar lock is designed to provide safe handling of the union collars In addition it can be used to prevent accidental back off of the collar The following shows the sequence for correct operation 3 1 1 Preparing the Safe Lok Collar After removing the thread protector the collar will be set in the lower position and must be moved to the high position before making up the connection With both hands raise the collar ensuring the Stop Pins go through the gaps in the raised rim Rotate the collar through 90 and gently lower onto the raised rim Ensure collar rests into the grooved area OPS 3954 Rev A QU Phuel OIL TOOLS 3 1 2 Making up the Safe Lok Collar Lift and stab the pin into the mating box and check that there are no signs of damage to the o ring caused by being misaligned while stabbing in With both hands raise the collar clear of the grooved area on the raised rim
9. h a wire brush and grease Fit O rings to the connection Apply grease to the O ring threads and OD Fit O ring to test port grease and fit to bottom sub using 2 screws and washers Fit O ring to valve grease and refit to check housing Fit circlip to check housing Fit O ring to isolation check housing grease and fit to bottom sub using 2 screws and washers Fit isolation check housing protector using 2 screws and washers OPS 3954 Rev A 11 User Manual Ewe Insitu Riser OIL TOOLS e Slide the Split Collar over the Riser Tube make up the two halves of the split ring and tighten down until the ends are flush with the collar Back off slightly to align the holes e Insert 4 Stop pins and washers to ensure the holes are aligned OPS 3954 Rev A 12 User Manual 733 Phuel Insitu Riser 5 5 Maintenance Record Sheet Date Type of Performed Verified Comments Performed Maintenance By By Table 2 Maintenance Record OPS 3954 Rev A 13 User Manual QU Phuel Insitu Riser 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 On completion of reassembly fit the appropriate test caps to e
10. ither end of the riser and NPT plug to the test port Fill with test fluid and bleed off any air in the system Apply a pressure of 500 psi and ensure pressure holds for a minimum of 10 minutes Increase pressure to Maximum Working Pressure refer Part No 110 3954 HVO i 1 Connections 9 QU Pin 8 Box Vo NPT Length A 60 74 1 54m Make up Length B 57 09 1 45m Weight 415lbs 188kgs Maximum Working Pressure 6 500 Psi Test Pressure 10 000 Psi Table 1 or Error Reference source not found 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 and plug 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 Para 5 5 Example is completed OPS 3954 Rev A 14 EL User Manual uel Insitu Riser OIL TOOLS 7 Parts List and Drawings Item Number MIB WIN re Part Number Description 110 3992 480 INSITU RISER 5 1 8 8 25B X 9 4P 110 2053 480 COLLAR 9 4 SPLIT TYPE 110 2054 480 SPLIT RING 9 4 145 2176 480 SAVER SUB PORT Quantity 1 Ril RP BR 900 3018 480 ISOLATION CHECK HOUSING 1 6 110 2979 316 VALVE 1 7 190 2823 PEK VALVE SEAT 1 8 110 3
11. om other suppliers at the sole risk of the user 8 1 2 Supporting Equipment The following test fixtures are available for order directly from Phuel Oil Tools Ltd Part No Item Description Comments 205 2105 480 Blank Test Sub 111 2493 HVO Lubricator Manifold 111 3482 HVO Riser Manifold Table 5 Supporting Equipment OPS 3954 Rev A 17
12. on Valve and Protector OPS 3954 Rev A 6 User Manual QU Phuel Insitu Riser 4 Operation All operations to be carried out by suitably qualified and competent personnel 4 1 Lifting Thread protectors should always be fitted when lifting or moving the riser 4 1 1 Vertical The Riser should be lifted with a suitable lifting clamp or cap that is rated for the total lifting load Following the instructions for the clamp or cap being used If practical leave the thread protectors fitted until ready to make up the connections 4 1 2 Horizontal Suitable slings can be wrapped around either end of the riser to allow horizontal lifting for means of transportation or fitting Always pay attention to the centre of gravity and do not continue to lift if the lubricator is not sitting horizontal as it might slip through the slings 4 2 Making Up the Riser e With the riser hanging vertically above the mating connection remove the thread protectors of both ends e Set the Safe lok collar to the high position ready for stabbing in e Inspect the o ring for any signs of damage and apply grease if required e Inspect the mating bore and thread for any signs of damage or debris and clean and grease if necessary e Lower the connection and centralise to ensure that the o ring is not loaded on one side Ensure that the connection has stabbed fully home and that there are no signs of o ring debris e Release the Safe lok collar and make up
13. ssure witnessed by certifying authority where applicable e Repaint OPS 3954 Rev A 10 User Manual QPhuel Insitu Riser 5 3 Safety Many of the components are heavy and should not be lifted without lifting aids 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 Redress Procedure 5 4 1 5 4 e e e e e e N Dis Assembly Place riser on the roller stands Remove 4 stop pins and washers from the split collar Loosen split rings from collar and remove from split collar Remove split collar from Riser Tube Remove 2 screws and washers from test port and remove port from bottom sub Remove 2 screws and washers from the isolation check housing protector Remove 2 screws and washers from the isolation check housing and remove the housing from the bottom sub Remove circlip from isolation check housing and remove valve Remove and discard all O rings Inspect all threads degrease and clean with wire brush Fit thread protectors Re Assembly Place the main tube section on the roller stands Remove the thread protectors Inspect the threads and clean wit
14. the threads until the Safe lok engages in the lower groove e Store the thread protectors in a safe place for use later 4 3 Breaking the connection e Ensure that all pressure is bled off The free movement of the collar is an indication of this e Unscrew the collar fully e Lift the collar and ensure the Stop Pins pass through the gaps in the raised rim rotate the collar 90 and lower gently into the grooved area OPS 3954 Rev A 7 User Manual 33 Phuel Insitu Riser of the rim Release the weight of the collar and ensure that it is supported correctly Lift up the riser to break the connection Visually inspect the o ring and male end to make sure that no damage has occurred Report if necessary Fit the thread protector to the bottom of the riser at this time to prevent damage when moving To do this the Safe Lok collar must be set to the low position Fit the thread protector to the other thread unless a lifting cap is being used 4 4 Replacing the Saver Sub It is not expected that the saver sub would need to be replaced during normal operations but if damage occurs to a pressure fitting or a leak is found during pressure testing then this procedure should be followed Ensure that the pressure is bled off Do not remove the pressure fittings at this time as they can be used to provide grip to remove the plug Remove the two socket head cap screws and lock washers If they appear unusually tight or difficult to move re
15. ve movement 4 8 Post Job Inspect for signs of damage especially to o rings and threads Ensure threads are clean Ensure thread protectors are fitted OPS 3954 Rev A 9 User Manual QPhuel Insitu Riser 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 Refer to Section 4 6 and Section 4 8 for details 5 2 2 Yearly e Disassemble riser see 5 4 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 Replace all elastomeric seals with items from redress kit Regrease components Re assemble see 5 4 2 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 surface NDE on all component threads and damaged surfaces e Pressure test to maximum working pre
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