Phuel 145-2884-HV0 User manual

OPS-2884 Rev E
Unit 17 Denmore Industrial Estate, Denmore Road, Bridge of Don, Aberdeen AB23 8JW
User Manual
Greasehead
145-2884-HV0

User Manual
Greasehead
145-2884-HV0
OPS-2884 Rev E i
Table of Contents
Revision History ........................................................................................... ii
Safety.............................................................................................................. iii
1 Introduction ...............................................................................................1
1.1 General..............................................................................................1
1.2 Product Identification .........................................................................1
2 Technical Specification .............................................................................2
3 Technical ..................................................................................................3
3.1 Description.........................................................................................3
3.2 Key Product Features ........................................................................5
4 Operation ..................................................................................................7
4.1 Lifting and Handling ...........................................................................7
4.2 Pre Job ..............................................................................................7
4.3 During Job .........................................................................................7
4.4 Post Job.............................................................................................9
5 Maintenance ...........................................................................................11
5.1 Introduction......................................................................................11
5.2 Schedule..........................................................................................11
5.3 Safety ..............................................................................................12
5.4 Tools................................................................................................12
5.5 Redress Procedure..........................................................................13
5.6 Maintenance Record Sheet .............................................................14
6 Testing ....................................................................................................15
7 Parts List and Drawings..........................................................................16
8 Spares ....................................................................................................20
Table 1:Technical Data ....................................................................................2
Table 2: Configuring to suit the wire.................................................................9
Table 3: Maintenance Record ........................................................................14
Table 4: Parts List ..........................................................................................16
Table 5 : Redress Kit Part No RDK-2884-HV0 ..............................................20
Table 6 : Supporting Equipment.....................................................................20
Figure 1: Grease Head Safety ........................................................................ iii
Figure 2: Grease Head ....................................................................................2
Figure 3: Pressure gradient inside the flow tube assembly..............................3
Figure 4: Couettes flow equation .....................................................................4
Figure 5: Fast Collar ........................................................................................5
Figure 6: Grease Head Assembly 1 ...............................................................17
Figure 7: Grease Head Assembly 2 ...............................................................19

User Manual
Greasehead
145-2884-HV0
OPS-2884 Rev E ii
Revision History
Issue, Release Date Description
Rev A, 20 Apr. 10 Initial Issue
Rev B, 27 Jul 10 Part No Cx 145-2969-V80 to PU8
items 20, 21 cx to W43
Rev C, 11 Jul 11 Parts list update, T-Seal material
hardness Cx from H70 to H80
Rev D, 31 Jan 12 Pg 10 Illustration Updated
Rev E, 28 Aug. 12 Pg 17 Added VIEW ‘E’

User Manual
Greasehead
145-2884-HV0
OPS-2884 Rev E iii
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 fitted, 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
Figure 1: Grease Head Safety
Finger, Glove and
loose clothing trap
area

User Manual
Greasehead
145-2884-HV0
OPS-2884 Rev E 1
1 Introduction
1.1 General
Phuel has transformed the greasehead functionality with the innovation of
using what are essentially small quick union connections on the flow tube
housings. This vastly improves, eases and speeds up the redressing
operations and allows the operator to align his hydraulic connection with ease.
The design utilises standard flow tubes and comes complete with ball check
valves and chemical injection facilities. The Phuel greasehead is designed for
up to 10,000psi working pressure, 15,000psi test pressure H2S service.
Higher working pressures can be obtained if required
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 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.
PHUEL OIL TOOLS LTD
DESCRIPTION & SIZE
CUSTOMER ID No
PHUEL ID No 06-XXX-XX
MWP & SERVICE
TEST DATE
PHUEL OIL TOOLS LTD
DESCRIPTION & SIZE
CUSTOMER ID No
PHUEL ID No 06-XXX-XX
MWP & SERVICE
TEST DATE

User Manual
Greasehead
145-2884-HV0
OPS-2884 Rev E 2
2 Technical Specification
Part Number 145-2884-HH0
Connections 5 ¾’’ Otis Type
2’’ NPT Male Top Thread
Maximum Working Pressure 10,000 Psi
Design Test Pressure 15,000 Psi
Service H2S
Weight 291 lbs / 132 kg
Overall Length (A) 118.11’’ / 3 m
Make Up Length (B) 114’’ / 2.90 m
Table 1: Technical Data
Figure 2: Grease Head

User Manual
Greasehead
145-2884-HV0
OPS-2884 Rev E 3
3 Technical
3.1 Description
The grease injection control head (greasehead) provides a pressure seal
around stationary or moving wireline that is run into or out of wells to prevent
the escape of well fluids to the environment. The assembly consists of a
hydraulic pack off and a series of flow tube assemblies.
The flow tube assembly consists of a number of close fitting steel tubes
through which the wire line passes. Each flow tube is approximately 14” long
and these are slipped onto the wire and connected together with the fast collar
connection to build up the required length. Viscous grease is injected between
the bore of the flow tube and the outside of the wire and travels along the
length of the flow tube stack creating a pressure drop. Grease injection
pressure can then be increased to about 25% more than the well pressure to
create a liquid seal that allows the wire to move but prevents the escape of
well fluids. The inside diameter of the flow tubes needs to be from 0.003” to
0.008” larger than the actual wire diameter for the seal to be effective so the
flow tubes must be selected based on the wire being used.
Figure 3: Pressure gradient inside the flow tube assembly
The length of flow tube required depends on the well pressure, the wire size,
the flow tube size, the grease viscosity and pump rate and the effectiveness of
the seal will depend on the pull out speed of the wire. The relationship for the
pressure drop can be expressed mathematically by Couettes flow equation.
This shows that the clearance between the wire and the flow tube has a great

User Manual
Greasehead
145-2884-HV0
OPS-2884 Rev E 4
effect on the pressure drop created as so this is the most important parameter
to consider.
Figure 4: Couettes flow equation
The actual diameter of the wire must be measured and recorded to allow the
correct diameter of flow tube to be selected. The condition of the wire must
also be considered as mud or rust ingress can cause the wire to swell.
Consideration also needs to be given to the wear of the flow tubes as these
tend to wear in the middle, where it is most difficult to measure the bore.
The grease is injected above the first flow tube and exits after the last one.
Since the grease is continuously moving and some is being lost to the well,
the injection process is continuous and in order to create sufficient flow rate it
may be necessary to inject at two locations depending on the well pressure.
The table below shows the recommended greasehead arrangement
depending on the well pressures. This is a guideline only.
Well Pressure Fluid No of flow tubes* No of Injection Points
0-5000 psi Liquid 4 1
0-5000 psi Gas 5 1
5-10,000 psi Liquid 6 1
5-10,000 psi Gas 7-8 1
10-15,000 psi Liquid 10 2
10-15,000 psi Gas 11-12 2
* including the flow tubes below the grease injection port(s)

User Manual
Greasehead
145-2884-HV0
OPS-2884 Rev E 5
3.2 Key Product Features
3.2.1 Fast Collar
The fast collar is designed to allow quick replacement of the folw tubes either
due to a requirement for a line size change or for repair. The fast collar is
released by unscrewing the collar from the connector sub, which bears
against the circlip to pull the seal out of the bore - allowing access to the flow
tube housing and the flow tube. This results in a fast and easy method of
configuring the greasehead and allows the injection and return ports to be
orientated as required.
Figure 5: Fast Collar
3.2.2 Dual Ported Connector Sub
The Connector Subs between each of the flow tube housings has two
opposing saver sub ports. Depending on the Saver Sub fitted these can either
be blanked off or used for pressure monitoring in between each flow tube if
required. This provides maximum
operational flexibility
3.2.3 Check Valve Saver Sub
The saver sub interface also allows a right
angled check valve assembly to be used
that angles the outlet at a suitable angle
to ease the management of the hoses and
provides a check valve to prevent well
fluids being returned to the grease skid.
These subs can be placed in any location
but are normally used in the chemical
injection port and the grease injection
port.
The check valve components can easily be removed to provide a simple right
angled port that may be used on the grease return line if only one injection
line is required.

User Manual
Greasehead
145-2884-HV0
OPS-2884 Rev E 6
3.2.4 Tension Pack off
The pack off assembly allows a rubber seal to be made against static wire in
order to prevent the escape of well fluids if the grease seal is lost. In some
greaseheads the packing can become energised by the flow of the grease
and can cause it to grip down on the wire and prevent or restrict the running of
the wire. The Phuel pack off element is located at both ends and is held in
tension to prevent this kind of problem from occurring.
3.2.5 Lower Pack off Option
As an option there is a lower pack off assembly that can be attached below
the lower flow tube to provide a lower pack off assembly. This can be used to
quickly re-establish the grease seal during operations rather than circulating
the grease all the way to the BOP.
The lower pack off would be closed with the upper one and grease circulated
through only the greasehead length without any losses in to well below. This
will provide a smaller volume for circulation and may eliminate the need to
close BOP on the wire – thus saving valuable operational time.

User Manual
Greasehead
145-2884-HV0
OPS-2884 Rev E 7
4 Operation
All operations to be carried out by suitably qualified and competent
personnel
4.1 Lifting and Handling
Thread protectors should always be fitted when lifting or moving the
greasehead.
4.1.1 Vertical
The greasehead should be lifted with a suitable lifting clamp or sling that is
rated for the total lifting load. Following the instructions for the clamp or sling
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 greasehead 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 greasehead is not sitting
horizontal as it might slip through the slings.
4.2 Pre Job
•Ensure thread protectors are fitted
•Check maintenance record sheet and ensure the equipment has been
maintained by competent personnel
•Check all certification is in date
•Confirm information band is fitted and correct
•Ensure equipment is suitable for the maximum working pressures and
services involved
•Ensure visible ‘O’ rings are seated correctly and there are no signs of
damage
•Ensure threads are clean
•Inspect for signs of damage
•Pressure test to maximum operating pressure
4.3 During Job
•Select the correct size of flow tubes according to the actual wire sizes
for the wire being used.
•Insert the wire as shown in the following diagram
•Rig up the hoses according to the diagram

User Manual
Greasehead
145-2884-HV0
OPS-2884 Rev E 8
4.3.1 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-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 ¼-20 UNC 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.
4.3.2 Removing the Check Valve Components
This will be required if the injection Check Valve Saver Sub is being moved to
the return port to provide a right angled port. The check valve can be re-
instated by following the procedure in reverse.
•With the check valve sub removed from the body
•Unscrew the Hollow Hex Plug using a suitable hex key
•Remove the spring and check valve and store in a safe place
•Replace the Hollow Hex Plug to act as a thread protector
•Refit the Check Valve sub to the required port.

User Manual
Greasehead
145-2884-HV0
OPS-2884 Rev E 9
4.3.3 Configuring to suit the wire
The Phuel greasehead is multi-line and so no special parts changes are
required to suit the diameter of the wire being used. Only the line wiper
module needs to be changes to ensure that the wiper works effectively.
The table below shows the parts that should be fitted for the range of wire
sizes.
Wire Interlocking
Seats Split Packing Packing Gland
Item No * 20 & 21 22 40
Qty 1 off each 2 off each 1 off set
3/16
145-3236-W43
(LEFT)
&
145-3237-W43
(RIGHT)
145-2969-PU8
145-2970-W43
7/32
1/4
5/16
3/8
7/16
15/32 145-3236-W47 145-2970-W47
* - Refers to drawing shown in Section 7.
Table 2- Configuring to suit the wire
4.4 Post Job
•Inspect for signs of damage
•Ensure threads are clean
•Ensure thread protectors are fitted

User Manual
Greasehead
145-2884-HV0
OPS-2884 Rev E 10
GREASE
WASTE
GLYCOL
GREASE
WASTE
GLYCOL

User Manual
Greasehead
145-2884-HV0
OPS-2884 Rev E 11
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 & Post Job
Refer to Section 4.2 and Section 4.4 for details
5.2.2 Yearly
•Disassemble Greasehead (see 5.5.1) clean and degrease all
components
•Inspect the condition of all sealing surfaces and surface coatings
•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 (see spares
Table 5)
•Regrease components
•Re-assemble (see 5.5.2)
•Pressure test to maximum working pressure in accordance to testing
procedure (see 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 certifying authority

User Manual
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OPS-2884 Rev E 12
5.3 Safety
•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
•3/8 hex Allen key
•7/8’’ Spanner (If NPT Plug to be fitted)
•Wire Brush

User Manual
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OPS-2884 Rev E 13
5.5 Redress Procedure
5.5.1 Dis-Assembly
•Remove the packoff assembly by unscrewing the uppermost Fast
Collar (6)
•Remove the Top Sub (1) and strip off the Saver Sub assembly
•Pump up the piston and remove the Interlocking seats (20 & 21)
•Remove the split Packing (22) and Packing Gland (40)
•Bleed off the piston pressure and disconnect the pump
•Remove the Seal Housing (2) and collect the spilled hydraulic fluid
•Remove the Spring (41)
•Remove the Piston (4)
•Remove all the Saver Sub assemblies from the Return Housing
•Remove the Flow Tube Housing (7) from the next Connector Sub (5)
•Strip off the Saver Sub assemblies from the Connector Sub
•Remove the Flow Tube if fitted
•Remove the Circlip (43) and remove the Fast Collar (6)
•Repeat this process until all Housings are removed
•Remove the Check valve port from the Bottom Sub
•Remove the Collar
•Remove the Retaining Ring (24), Ball Cup (25) and Ball (42)
•Remove the Check Valve Seat (23)
•Remove all seals from the individual components without damaging the
surface of the sealing groove. Only do this if new seals are being fitted
– otherwise leave the seals as they are and inspect for signs of
damage or wear.
5.5.2 Re-Assembly
Re-assembly is the reverse to dis-assembly
•Ensure fresh seals are used from a redress kit and verify that the expiry
date has not been exceeded
•Inspect all seal grooves and bores for signs of scratches. Clean up if
required with fine emery cloth
•Fit the seals avoiding excessive stretch and lightly coat with grease

User Manual
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5.6 Maintenance Record Sheet
Date
Performed
Type of
Maintenance
Performed
By
Verified
By
Comments
Table 3: Maintenance Record

User Manual
Greasehead
145-2884-HV0
OPS-2884 Rev E 15
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 caps and blanking plugs. No flow tubes are required
for a body test
•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 pressure 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 and shipping cap plugs
On completion of all maintenance ensure the maintenance record sheet (Para
5.6) is completed

User Manual
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145-2884-HV0
OPS-2884 Rev E 16
7 Parts List and Drawings
Item Number Part Number Quantity Description
1 145-2976-480 1 TOP SUB
2 145-2971-480 1 SEAL HOUSING
3 145-2974-480 1 RETURN HOUSING
4 145-2966-480 1 PISTON
5 145-2975-480 5 CONNECTOR SUB
6 145-2120-480 6 FAST COLLAR
7 145-2121-480 6 FLOW TUBE HOUSING
8 145-2123-480 1 BOTTOM SUB
9 100-1984-480 1 COLLAR (5 75-4)
10 145-2176-480 6 SAVER SUB PORT
11 205-2105-480 5 BLANK TEST PORT
12 900-3019-480 3 CHECK HOUSING
13 145-3248-480 1 SAVER SUB (10MM HOLE)
20 145-3236-W31 1 INTERLOCKING SEAT - LEFT
21 145-3237-W31 1 INTERLOCKING SEAT - RIGHT
22 145-2969-PU8 2 SPLIT PACKING
23 145-2126-B21 1 CHECK VALVE SEAT
24 145-2128-B21 1 RETAINING RING
25 145-2127-PTF 1 BALL CUP
29 801-0234-V90 1 O-Ring - B.S Size 234
30 802-2977-H80 2 PISTON T-SEAL (2.00)
31 802-2183-H80 1 PISTON T-SEAL (3.250)
33 801-0210-V90 12 O-Ring - B.S Size 210
34 801-0223-V90 6 O-Ring - B.S Size 223
35 801-0224-V90 6 O-Ring - B.S Size 224
36
801
-
0342
-
V90
1
O
-
Ring
-
B.S Size 342
37 801-0119-V90 15 O-Ring - B.S Size 119
38 801-0225-V90 1 O-Ring - B.S Size 225
40
145
-
2970
-
W43
1
PACKING GLAND 7/16
41 145-2177-STL 1 PISTON SPRING
42 145-2181-316 1 BALL BEARING 0.750 DIA
43 145-2180-STL 6 EXTERNAL CIRCLIP (DSH-50)
44 190-1749-X75 3 Compression Spring
45 190-2786-PEK 3 CHECK CONE SEAL
46 190-1703-STL 3 Hollow Lock Screw 3/4-16 (MAC-765)
47 SHC-0583-3A4 30 Soc Hd Cap 1/2 UNC Length 3/4 in
49 WNL-0580-316 30 WASHER NORDLOCK (M12)
50 145-2215-304 6 SPLIT COTTER PIN 1/8 X 3 LONG
97 910-2184-N66 1 THREAD PROTECTOR 2in NPT
98 910-2186-N66 9 1/2in SHIPPING CAP PLUG
100 910-3541-N66 1 DW MALE PROTECTOR 5-3/4
Table 4: Parts List