Phuel 145-4427-HV0 User manual

OPS-4427 Rev A
Unit 17 Denmore Industrial Estate, Denmore Road, Bridge of Don, Aberdeen AB23 8JW
User Manual
15K Grease Head
8 ¾-4 Quick Union (5’’ Seal Bore)
This Manual Covers the Following Part Numbers:
145-4427-HV0

User Manual
Grease Head
OPS-4427 Rev A i
Table of Contents
Revision History ...........................................................................................ii
Safety.............................................................................................................. iii
1Introduction...............................................................................................1
1.1 General..............................................................................................1
1.2 Product Identification.........................................................................1
2Technical Specification.............................................................................2
3Technical ..................................................................................................4
3.1 Description.........................................................................................4
3.2 Key Product Features........................................................................6
4Operation..................................................................................................8
4.1 Lifting and Handling...........................................................................8
4.2 Setting Up..........................................................................................8
4.3 Pre Job............................................................................................10
4.4 During Job.......................................................................................10
4.5 Post Job...........................................................................................11
5Maintenance...........................................................................................12
5.1 Introduction......................................................................................12
5.2 Schedule..........................................................................................12
5.3 Safety ..............................................................................................13
5.4 Redress Procedure..........................................................................13
5.5 Maintenance Record Sheet .............................................................18
6Testing....................................................................................................19
7Parts List and Drawings..........................................................................20
8Spares ....................................................................................................25
Table 1: Technical Data...................................................................................2
Table 2: Recommended Grease Head Arrangement (Guidance only).............5
Table 3: Maintenance Record........................................................................18
Table 4: Parts List 145-4427-HV0..................................................................21
Table 5 : Redress Kit Part No RDK-4427-HV0 ..............................................25
Figure 1: Grease Head Safety ........................................................................ iii
Figure 2: Grease Head ....................................................................................2
Figure 3: Grease Head Connections................................................................3
Figure 4: Pressure gradient inside the flow tube assembly..............................4
Figure 5: Couettes flow equation .....................................................................5
Figure 6: Fast Collar ........................................................................................6
Figure 7: Fitting the packing.............................................................................9
Figure 8: Assembly guide –part 1 .................................................................15
Figure 9: Assembly guide –part 2 .................................................................16
Figure 10: Assembly guide –part 3 ...............................................................17
Figure 11: Grease Head Assembly................................................................22
Figure 12: Grease Head Assembly Detail......................................................24

User Manual
Grease Head
OPS-4427 Rev A ii
Revision History
Issue, Release Date
Description
Rev A, 22 Feb. 12
Initial Issue

User Manual
Grease Head
OPS-4427 Rev A 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.
Seals in high-pressure vessels are also susceptible to explosive
decompression; the O-rings or rubber gaskets used to seal pressurised
pipelines tend to become saturated with high-pressure gases. If the
pressure inside the vessel is suddenly released, then the gases within
the rubber gasket may expand violently, causing blistering or explosion
of the material.
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
Grease Head
OPS-4427 Rev A 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 15,000psi working pressure and H2S service.
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.

User Manual
Grease Head
OPS-4427 Rev A 2
2 Technical Specification
Part Number
145-4427-HV0
Connections
8 ¾-4’’ Quick Union (5’’ Seal Bore)
2’’ NPT Male Top Thread
Maximum Working Pressure
15,000 Psi
Design Test Pressure
22,500 Psi
Service
H2S
Weight
610 lbs / 277 kg
Overall Length
210.78’’ / 5.35m
Make Up Length
207.64’’ / 5.28m
Port Connections
9/16 Autoclave MP
Line Wiper Return
½” NPT
Piston Pressure
½” NPT
Earthing Tapped Hole
M12 x 12mm deep
Table 1: Technical Data
Figure 2: Grease Head

User Manual
Grease Head
OPS-4427 Rev A 3
Figure 3: Grease Head Connections
Grease Monitor
Grease Injection with
Check Valve
Hydraulic Pack-Off
Hydraulic Pack-Off
Grease Monitor
Grease Return
Line Wiper Air
Inlet
Line Wiper
Return
Optional Drain

User Manual
Grease Head
OPS-4427 Rev A 4
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 4: 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
effect on the pressure drop created as so this is the most important parameter
to consider.

User Manual
Grease Head
OPS-4427 Rev A 5
Figure 5: 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)
Table 2: Recommended Grease Head Arrangement (Guidance only)

User Manual
Grease Head
OPS-4427 Rev A 6
3.2 Key Product Features
3.2.1 Fast Collar
The fast collar is designed to allow quick replacement of the flowtubes 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 6: 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.