Phuel 108-3108-HV0 User manual

OPS-3108 Rev E
Unit 17 Denmore Industrial Estate, Denmore Road, Bridge of Don, Aberdeen AB23 8JW
User Manual
Turnaround Sheave
108-3108-HV0/HV1

User Manual
Turnaround Sheave
108-3108-HV0
108-3108-HV1
OPS-3108 Rev E 1
Table of Contents
Revision History ...........................................................................................2
Safety...............................................................................................................3
1Introduction...............................................................................................4
1.1 General..............................................................................................4
1.2 Product Identification .........................................................................4
2Technical Specification .............................................................................5
3Technical Description ...............................................................................9
4Operation................................................................................................10
4.1 Pre Job ............................................................................................10
4.2 During Job .......................................................................................10
4.3 Post Job...........................................................................................10
4.4 Changing the Pulley Wheel .............................................................11
4.5 Fitting the Tool Catcher ...................................................................13
5Maintenance ...........................................................................................14
5.1 Introduction......................................................................................14
5.2 Schedule..........................................................................................14
5.3 Maintenance Record Sheet .............................................................16
6Testing....................................................................................................17
7Parts List and Drawings..........................................................................18
8Spares ....................................................................................................24
8.2 Optional Equipment .........................................................................24
Table 1: Technical Specification ......................................................................5
Table 2: Maintenance Record........................................................................16
Table 3: Part List for 108-3108-HV0 ..............................................................18
Table 4: Parts List for 108-3108-HV1.............................................................19
Table 5: Parts List for 108-4131-HV0.............................................................20
Table 6: Part List for Handling Kit 108-3508-SS0 ..........................................20
Table 7: Redress Kit Part No RDK-3108-HV0 ...............................................24
Table 8: Redress Kit Part No RDK-3108-HV1 ...............................................24
Table 9: Optional Equipment .........................................................................24
Table 10: Maximum Safe Riser Length for Given Line Pull..............................5
Figure 1: Turnaround Sheave Safety ...............................................................3
Figure 2: Specification drawing (dimensions in inches) ...................................6
Figure 3: Specification drawing (dimensions in mm)........................................7
Figure 4: Assembly & Disassembly Instructions ............................................15
Figure 5: Tool Catcher Adapter Assembly .....................................................20
Figure 6: Turnaround Sheave Assembly........................................................21
Figure 7: Alternative Wheel Part Nos.............................................................22
Figure 8: Handling Kit ....................................................................................23
Figure 9: Typical Hook-Up Arrangement..........................................................2

User Manual
Turnaround Sheave
108-3108-HV0
108-3108-HV1
OPS-3108 Rev E 2
Revision History
Issu
e, Release Date
Description
Rev A, 24 April 2010 Initial Issue
Rev B, 22 June 2010 Fitting Tool Catcher Added
Rev C, 13 June 2011 Tool Catcher Adaptor Assembly Added
Rev D, 17 Jan 2014 Corrected Pulley Wheel Part Nos
Rev E, 15 Jan 2015 Added Lift Declaration

User Manual
Turnaround Sheave
108-3108-HV0
108-3108-HV1
OPS-3108 Rev E 3
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 utilise the appropriate PPE.
Ensure the identification plate is fitted and is displaying the correct information
as per the documentation supplied
This equipment and the equipment it is attached to is heavy never position
yourself below a suspended load
When lifting consider the effective balance point of the assembly and avoid
excessive bending at the end connections
Figure 1: Turnaround Sheave Safety
Avoid Excessive bending at
these points

User Manual
Turnaround Sheave
108-3108-HV0
108-3108-HV1
OPS-3108 Rev E 4
1 Introduction
1.1 General
The Phuel 20” Turnaround Sheave (TAS) was developed to maximise the
height available above the wellhead in situations where height is an issue.
The Phuel TAS is designed for 10,000psi working pressure and H2S service
and can be offered with a Phuel Iris Tool catcher built in. It can be dressed for
any size of line up to 7/16” dia.
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 customer identification number is also
included to allow the customer to track the asset in their system.
A stainless steel band or rivets secures the nameplate tag that is stamped
with the information shown below. This tag should be located in the first
instance to ensure that this manual refers to the correct equipment.

User Manual
Turnaround Sheave
108-3108-HV0
108-3108-HV1
OPS-3108 Rev E 5
2 Technical Specification
Test Connections ½’’ NPT Grease Injection (P1)
½” NPT Gas Bleed Off (P2)
Sensor Housing (P3) or Blank
Maximum Working Pressure 10,000 Psi (690 bar)
Maximum Test Pressure 15,000 Psi (1035 bar)
Safe Lifting Load 6-1/2 Ton
Weight 876 lbs (398 Kg) – 108-3108-HV0
847 lbs (385 Kg) – 108-3108-HV1
Temperature Range -18ºC to 121ºC
Grease Pumping Rate 1 – 2 Strokes per Min during Operation
Max Line Pull Refer to Table 7 Annex A
Table 1: Technical Specification

User Manual
Turnaround Sheave
108-3108-HV0
108-3108-HV1
OPS-3108 Rev E 6
Figure 2: Specification drawing (dimensions in inches)

User Manual
Turnaround Sheave
108-3108-HV0
108-3108-HV1
OPS-3108 Rev E 7
Figure 3: Specification drawing (dimensions in mm)

Phuel Oil Tools Ltd
Unit 12 Barratt Trading
Estate
Denmore Road
Bridge of Don
Aberdeen
AB23 8JW
Tel [phone]
Fax [phone]
For safe operation and proper maintenance of this equipment, refer to the operating manual
Phuel Ol Tools Ltd operates a quality system that conforms to ISO 9001:2008
and is registered with BSI-Certificate No FS 511512
OPS-3108 Rev E 8
Part Number: 108-3108-HV0
Description: 20" TAS 5-3/4 10K
Working Pressure: N/A
Temperature: -18°C TO +121°C
Pad eye SWL: 6.5 TONNE (6,500 Kg)
Certified to: API 6A: 20
th
Edition: 2010
API SPEC 8C: 5
th
Edition: 2012
NACE MR0175 / ISO 15156:2009
This document certifies that the products listed above comply with the relevant
provisions of the Machinery Directive 2006/42/EC
Name: Title:
Sign: Date:
For & on behalf of Phuel Oil Tools Ltd, Aberdeen

User Manual
Turnaround Sheave
108-3108-HV0
108-3108-HV1
OPS-3108 Rev E 9
3 Technical Description
The Phuel Turnaround Sheave provides the maximum tool string height in the
riser, while preserving the life of the wire by extending the wheel diameter to
20inches – making it suitable for the larger wire diameters. Magnets have
been incorporated into the wheel so that the Phuel Detection system can be
used to confirm that the wheel is turning – providing extra assurance during
operations.
The wheel is supported on two ball bearings mounted inside a housing and
secured with a Seal Ring at one end, which is locked in place by a series of
inner and outer plates. The plates are equally spaced around the
circumference of the seal ring and secured with screws to prevent movement.
The Housing provides three lifting eyes so that the balance of the riser weight
can be accommodated while lifting. The outermost eyes are positioned so as
to provide an almost perfect balance point when the lubricators are attached
to make the handling and stabbing in process easier.
An alternative Bottom Sub can be provided to allow the Phuel IRIS tool
catcher to be directly incorporated without wasting more riser height and the
other adapter allows the Grease head to be directly connected without the
need for any disassembly of its lower section.
At the top end there is a ½” NPT connection to facilitate the bleed off of gas if
it breaks out from the wire during operations. The lower grease injection ports
(½” NPT) are used to prevent the well debris from entering the bearings
during operations. A grease pump must be connected and set up so that
grease is constantly being pumped through at a rate of 1 – 2 strokes per
minute during operations irrespective of the operating pressures to maximise
the life of the bearings.
The NPT connects are cut into the Phuel saver Sub, which is a removable
part that can be easily replaced if damaged without the need to repair the
main housing. This port is a standard interface to many alternative Phuel parts
so blank ports, check valves, valve manifolds or isolating valves can be
attached here to suit the required operation. Contact Phuel for more details if
required.

User Manual
Turnaround Sheave
108-3108-HV0
108-3108-HV1
OPS-3108 Rev E 10
4 Operation
All operations to be carried out by suitably qualified and competent
personnel
4.1 Pre Job
•Confirm identification information plate is fitted and correct
•Check maintenance record sheet and ensure the equipment has been
maintained by competent personnel
•Check all certification is in date
•Ensure equipment is suitable for the maximum working pressures and
services involved
•Ensure threads are clean
•Inspect for signs of damage
•Fill turnaround Sheave with clean grease
•If using the Phuel Detection System Insert a length of wire and confirm
that the wheel is moving freely. (See Section 6).
•Pressure test to the maximum operating pressure
•Ensure all connections are tight
•Ensure correct Pulley Wheel for the wire being used is fitted
•To avoid tilting during lifts it is recommended that 2 lifting points are
used to lift the equipment into place
4.2 During Job
•Using suitable pump fill TAS with clean grease
•Secure the TAS to the mast to prevent excessive movement
•Use the sensor to show that the wheel is turning as expected. If not
using Detection System rotation is indicated by the difference in the
Up/Down weights while spooling wire
•Ensure that grease is always being pumped from the inside of the
bearings outwards to the well adjust so that pump maintains a stroke of
1 – 2 strokes per minute.
•Bleed off any build up of gas at the top of the wheel if required
4.3 Post Job
•Inspect for signs of damage and report any findings
•Ensure threads are cleaned and the re-greased
•Pump through with clean grease ensuring that there is no pressure lock
and check that the wheel turns freely
•If debris is found in the system a full strip and rebuild is required
•Fit protectors to retain the grease fit sensor protector

User Manual
Turnaround Sheave
108-3108-HV0
108-3108-HV1
OPS-3108 Rev E 11
4.4 Changing the Pulley Wheel
Remove the Inner and Outer
Plates
Tip – The plates may be
squeezed by the Seal Ring so
knock the Seal Ring down to
release the load on the plates.
[Use the 2in long screws from
the Handling Kit screw into the
seal ring and strike with a soft
face hammer]
Use the Handling Kit to remove
the Seal Ring
Ensure that the internal volume
is open to atmosphere to avoid
creating a vacuum
Tip – Tighten the screws a little
amount each time ensuring that
they are all being extended
equally. When the seal is free
the Seal Ring can be lifted off.
Removing the Pulley
Use two suitable screws and
attach to the wheel.(Pulley
wheel has ¼” holes, handling
kit does not include ¼” screws)
Use pliers to grip the screws to
enable the wheel to be lifted out
The lower bearing may remain
in the Housing – there is
usually no need to remove this
unless it is damaged

User Manual
Turnaround Sheave
108-3108-HV0
108-3108-HV1
OPS-3108 Rev E 12
Replace the Wheel and
Bearing
Use the Handling Kit to push
the Seal Ring fully down
Tip – Tighten the screws a little
amount each time ensuring
that they are all being extended
equally.
Replace the Inner and Outer
Plates and secure with the
screws and Nordloc washers
Tip – Position the Plates so
that the four tapped holes in
the Seal Ring are not covered.
This ensures that they can be
used again when dis-
assembling.
Update the documentation
Tip- Write or label the
assembly with the pulley size
just fitted.
Tip – The size of the pulley
fitted may be determined by
removing the sensor housing
(or blank) and inspecting by
eye

User Manual
Turnaround Sheave
108-3108-HV0
108-3108-HV1
OPS-3108 Rev E 13
4.5 Fitting the Tool Catcher
Fit the Tool Catcher adaptor to the
Turnaround Sheave (if not already
fitted)
Split Tool Catcher down removing the
Top Sub, Finger Hub and top fingers,
Shock Absorber and Spacer Spring.
(Refer to relevant Tool Catcher manual
for information on how to carry this out)
Take split down Tool Catcher and attach
to the Adaptor fitted to the Turnaround
Sheave

User Manual
Turnaround Sheave
108-3108-HV0
108-3108-HV1
OPS-3108 Rev E 14
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 are considered to be the minimum requirements.
5.2.1 Pre & Post Job
Refer to Section 4.1 and Section 4.3 for details
5.2.2 Yearly
•Disassemble Turnaround Sheave (see Figure 4: Assembly &
Disassembly Instructions) clean and degrease all components
•Inspect the condition of all sealing surfaces and surface coatings. If in
doubt contact Phuel Oil Tools Ltd for advice
•Re-lubricate threads and sealing surfaces.
•Replace all elastomeric seals with items from redress kit (see spares
Section 8)
•Re-grease components
•Re-assemble (see Figure 4: Assembly & Disassembly Instructions)
•Pressure test to maximum working pressure in accordance to testing
procedure (see Para 6)
•Inspect paint work and repair as necessary
5.2.3 Five Yearly
•Yearly Maintenance (plus the following)
•Carry out 100% surface NDE on all surfaces
•Pressure test to test pressure witnessed by verifying body
•Repaint

User Manual
Turnaround Sheave
108-3108- HV0
108-3108-HV1
OPS-3108 Rev E 15
Figure 4: Assembly & Disassembly Instructions

User Manual
Turnaround Sheave
108-3108-HV0
108-3108-HV1
OPS-3108 Rev E 16
5.3 Maintenance Record Sheet
Date
Performed
Type of
Maintenance
Performed
By
Verified
By
Comments
Table 2: Maintenance Record

User Manual
Turnaround Sheave
108-3108-HV0
108-3108-HV1
OPS-3108 Rev E 17
6 Testing
All testing to be carried out in a designated test area 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 caps and blanking plugs
•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 5 minutes. Bleed pressure off
•Increase pressure to Maximum Working Pressure, allow to stabilise,
maintain this pressure for 5 minutes and bleed off then re-pressurise to
Maximum Working Pressure, allow to stabilise, maintain this pressure
for 15 minutes ensure there are no apparent leaks.(Testing to be
carried out to test pressure only when decreed by maintenance
schedule)
•Bleed off pressure, drain test fluid and dry (only if test fluid is water
based)
•Remove test caps
•Attach grease pump and fill with clean grease, Insert a length of wire
and use the sensor to confirm that the wheel is moving freely.
•Fit thread and sensor protectors
On completion of all maintenance ensure the maintenance record sheet (5.3)
is completed

User Manual
Turnaround Sheave
108-3108-HV0
108-3108-HV1
OPS-3108 Rev E 18
7 Parts List and Drawings
Item Number
Part Number
Quantity
Description
1 108-3250-
480
1 HOUSING
2 108-3251-
480
1 SEAL RING
3 108-3252-H
31
1 PULLEY WHEEL (5/16)
4 108-3254-
411
6 OUTER PLATE
5 108-3255-
411
6 INNER PLATE
6 108-3258-
480
1 TAS TOP SUB (5.75-4)
7 108-3777-
HV0
1 TAS 10K BOTTOM SUB ASSEMBLY
8 145-2176-
480
2 SAVER SUB PORT
9 206-1770-
NI5
1 SENSOR HOUSING
12 108-3373-STL 2 THIN ROLLER BEARING (KAYDON
KF180XP0)
13 190-1758-
416
1 AFO Plug (PLAA3124010A)
14 801-0387-
H90
1 O-Ring - B.S Size 387
15 801-0389-
H90
1 O-Ring - B.S Size 389
16 801-3437-
GRF
1 BACK UP RING TO SUIT 387
17 801-3436-
GRF
1 BACK UP RING TO SUIT 389
18 801-0326-
V90
1 O-Ring - B.S Size 326
19 801-0119-
V90
3 O-Ring - B.S Size 119
21 SHC-0583-
3A4
4 Soc Hd Cap 1/2 UNC Length 3/4 in
22 SHC-0586-
HTS
2 Soc Hd Cap Size 1/2 Length 1.25 in
24 WNL-0580-
316
6 WASHER NORDLOCK (M12)
26 WNL-0520-
304
24 Nord Lock Washer Size M8 (5/16)
27 SHF-0527-
HTS
24 Soc Hd Cap 5/16 UNF x 1.25 Long
30 108-3508-
SS0
1 TAS V2 HANDLING KIT
Table 3: Part List for 108-3108-HV0

User Manual
Turnaround Sheave
108-3108-HV0
108-3108-HV1
OPS-3108 Rev E 19
Item Number
Part Number
Quantity
Description
1 108-3250-
480
1 HOUSING
2 108-3251-
480
1 SEAL RING
3 108-3252-H
31
1 PULLEY WHEEL (5/16)
4 108-3254-
411
6 OUTER PLATE
5 108-3255-
411
6 INNER PLATE
6 108-3258-
480
1 TAS TOP SUB (5.75-4)
7 108-4131-
HV0
1 TOOL CATCHER ADAPTER ASSEMBLY
8 145-2176-
480
2 SAVER SUB PORT
9 206-1770-
NI5
1 SENSOR HOUSING
12 108-3373-
STL
2 THIN ROLLER BEARING (KAYDON
KF180XP0)
13 190-1758-
416
1 AFO Plug (PLAA3124010A)
14 801-0387-
H90
1 O-Ring - B.S Size 387
15 801-0389-
H90
1 O-Ring - B.S Size 389
16 801-3437-
GRF
1 BACK UP RING TO SUIT 387
17 801-3436-
GRF
1 BACK UP RING TO SUIT 389
19 801-0119-
V90
3 O-Ring - B.S Size 119
20 801-0326-
V90
2 O-Ring - B.S Size 326
21 SHC-0583-
3A4
4 Soc Hd Cap 1/2 UNC Length 3/4 in
22 SHC-0586-
HTS
2 Soc Hd Cap Size 1/2 Length 1.25 in
24 WNL-0580-
316
6 WASHER NORDLOCK (M12)
26 WNL-0520-
304
24 Nord Lock Washer Size M8 (5/16)
27 SHF-0527-
HTS
24 Soc Hd Cap 5/16 UNF x 1.25 Long
30 108-3508-
SS0
1 TAS V2 HANDLING KIT
Table 4: Parts List for 108-3108-HV1