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User Manual Grayloc Riser

1. Fit protectors On completion of all maintenance ensure the maintenance record sheet Para 5 4 is completed OPS 3068 Rev C 10 User Manual A Fuel Grayloc Riser OIL TOOLS 7 Parts List and Drawings 1 115 3120 480 1 15K RISER 3 74M GRAYLOC M12 72 W 3 06 BX 2 128 2216 A2H 8 HEAVY DUTY NUT 1 125 8 UN 3 900 3253 STL 1 ISEAL RING BX 154 Soft Iron 4 125 3357 AB7 8 STUDS 1 125 8 UN X 6 LONG 5 950 3366 475 1 3 1 16in BLANK FLANGE 15k Table 3 Parts List 115 3068 Note The nuts 2 are to be torqued to 523 ft lbs 706 Nm 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 8 1 1 Individual Items Individual items may be ordered as required using the part number specified 8 1 2 Supporting Equipment The following are available for order directly from Phuel Oil Tools Ltd or can be procured directly from your local Grayloc distributer if marked thus Item Description A90501 9 Grayloc Clamp 12M AISI 4140 NACE ASTM A 193 B7M H90136 17 Studs amp Nuts for ASTM A193 B7 A194 Gr2H Zinc Plated Clamp 12M 66814 Seal Ring Size 72 AISI 4140 NACE PTFE Coated A91072 4 Blind Test Hub Size 12M 72 with 9 16 Autoclave 950 3825 STL Lubricator Lift Clamp 25 Ton SWL with 2m of chains Table 4 Supporting Equipment OPS 3068
2. E OPS 3068 Rev C 1 User Manual Grayloc Riser 2 Technical Specification Part Number 114 3064 o 6375 Se A 147 21 3 74m Weight Weight Maximum Working Pressure Maximum Test Presure End Connection Table 1 Technical Data eg SS SSAC Figure 2 Riser OPS 3068 Rev C User Manual A Phuel Grayloc Riser OIL TOOLS 3 Technical Description 3 1 Metal Seal Ring The seal ring resembles a T cross section The leg of the T forms a rib that is held by the hub faces as the connection is made up The two arms form lip seals that create an area of sealing surface with the inner surface of the hub Internal pressure works to reinforce this seal 3 2 Two Hubs The clamp fits over the two hubs and forces them against the seal ring rib As the hubs are drawn together by the clamp assembly the seal ring lips deflect against the inner sealing surfaces of the hubs This deflection elastically loads the lips of the seal ring against the inner sealing surface of the hub forming a self energized seal 3 3 Clamp Assembly Designed to provide nearly 360 clamping contact with the hubs A relief notch in the centre of the clamp segments allow even distribution of makeup forces No specific orientation is required when installed Clamping Surface ring engage the inner hub surface with an interference fit which deflects the lips to achieve a seal OPS 3068 Rev C 3 User Man
3. Pe Unit 17 Denmore Industrial Estate Denmore Road Bridge of Don Aberdeen AB23 8JW User Manual Grayloc Riser This Manual Covers the Following Part Numbers 115 3068 HVO OPS 3068 Rev C User Manual IG Phuel Grayloc Riser OIL TOOLS Table of Contents Revision History ccccceeccceeeceeeceeeeseeceeeeeeeeseeceueeseeseeeseueeseeeseeesaueeneeeneeesaes i Sa LS EN li E Vun eeleren RE 1 We e EEE 1 NEE vele Leg e Et ere EE 1 SEENEN 2 3 Technical Description rrrnrnnnnennnrnnnnennnennnrnnnnennnennnrnnnnnnanennnrnnnnnnnnennnennnne 3 eal MSN 3 32 Two Hubs E 3 323 NAN 3 EE 4 GR 4 42 el e EE 4 BO AS SSM ONY eee 5 4 4 Disassembly A 6 e EN e D 6 dp During Job 6 ar PIN 6 5 E e e er 7 ol rg eil Ter e EE 7 EE 61 1 10 0 ene eee EE eee ee 7 Do O E E E E 8 5 4 Maintenance Record Sheet ccccccsseccceeseeceeseeeeeeeseeeeeseeeeeseeees 9 TN 10 7 Parts List and Drawings rorrrnnrennnennnnrrnrernnennnrnnnnennnennnnnnnnennnennnnnnnnennsen 11 Table 1 TE MANDAG 2 Table 2 Maintenance Record nnnennnnnnennnennsnnnsnnnnnnnnrrnnrrnnrrnrrnnrrsnresrennnrnnee gt 9 Tables Pane WRIST ER 11 Figure 1 Riser Safety rrrrnrrnnnnrrnrnnnrnrnnnrnrnnnrnrnnnenrannennannennnnnennansnnnnnsnnnnnsnnnnn li left EE 2 AES GIR 12 OPS 3068 Rev C i User Manual Phuet Grayloc Riser OIL TOOLS Revision History Issue Release Date Rev A 29 Oct 10 Initi
4. Rev C 11 OS SS OPS 3064 Rev NISS ey S User Manual 15K Risers All Lengths oo
5. al Issue Rev B 10 Jan 11 Seal Ring was BX 156 Sect 7 Rev C 11 Jan 11 Supporting Equipt Update OPS 3068 Rev C li Care to be taken to avoid trapping fingers gloves and loose clothing during stabbing procedure User Manual QPhuel Grayloc 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 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 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 loa
6. d Figure 1 Riser Safety OPS 3068 Rev C lil User Manual Fuel Grayloc Riser OIL TOOLS 1 Introduction 1 1 General The Phuel Grayloc 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 one piece with a metal to metal Grayloc sealing end connections 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 06 XXX XX MWP amp SERVICE TEST DAT
7. ing 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 User Manual IG Phuel Grayloc Riser 5 4 Maintenance Record Sheet Performed Maintenance By By Table 2 Maintenance Record OPS 3068 Rev C 9 User Manual Fuel Grayloc Riser 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 On completion of reassembly fit the appropriate test caps to either end of the riser 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 allow to stabilise and maintain this pressure for a minimum of 15 Minutes ensuring there are no apparent leaks Bleed off pressure drain test fluid and dry Remove test caps and plug Apply coating of de watering solution to protect the bore
8. n date e Confirm information band is fitted and correct e Ensure equipment is suitable for the maximum working pressures and services involved e Inspect for signs of damage e Pressure test to at least 1 2x the maximum well pressure e Ensure all connections are tight 4 6 During Job e Avoid excessive movement 4 7 Post Job e Inspect for signs of damage e Ensure protectors are fitted OPS 3068 Rev C User Manual A Phue Grayloc 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 Special maintenance is not required for a Grayloc connector that has been properly assembled However when disassembling a connector check the seal ring for standoff prior to reassembly and visually inspect the hub seats for uniformity and freedom from burrs and deep scratches These irregularities on ring seal surfaces could cause leakage Remove scale rust burrs or deep scratches from a ring seat by lightly polishing with a fine steel wool or crocus cloth around the seat circumference to ensure uniform blending in of the reworked area Never lap the hub seat with the seal ring this practice will damage both the ring and the seat and preven
9. reaction loads the torque values of 870 Ibft 1180 Nm is recommended Note that torque wrenches are not required but are recommended to ensure that the minimum preload values are met e Assembly should include jarring the clamps during the bolting procedures i e a sound blow to the back of the clamp with a soft hammer torque jar torque jar etc until bolt torque does not change after jarring e At full make up the hub faces will shoulder flush against the seal ring rib The seal ring rib will prevent over torquing from causing seal damage but to prevent permanent damage from distortion of the other components of the connection the maximum torque applied to the connection should not be more than twice the values shown in the table For extreme misalignment and or extreme piping loads torque values 1 h to 2 times the table values are recommended Lubricated bolting should be used to assemble the Grayloc connector OPS 3068 Rev C 5 User Manual A Fuel Grayloc Riser OIL TOOLS 4 4 Disassembly Before disassembling the Grayloc connector bleed all pressure from the line When removing the clamp first loosen the bolting and the clamp set from the hubs to allow the safe release of any trapped pressure Then remove the bolting completely 4 5 Pre Job e Ensure end protectors are fitted e Check maintenance record sheet and ensure the equipment has been maintained by competent personnel e Check all certification is i
10. ricant is recommended e When applying lubricant take special care to ensure that no solid or foreign particles are present in the lubricant Also take care to prevent mechanical damage to the seal ring and the hub sealing surfaces e Before assembly the hubs must be aligned to allow engagement of the seal ring lips to the hub sealing surfaces This will ensure proper engagement of the hub and clamp segments OPS 3068 Rev C 4 User Manual A Phue Grayloc Riser OIL TOOLS 4 3 Assembly e Align the hubs so that the seal ring can be installed between the hubs e Install the seal ring in the sealing surface of the hubs The seal ring should rock slightly i e the seal ring rib should not be able to firmly contact the hub face If it does not rock use a new seal ring e Install the clamps around the hubs Apply lubrication to the hub clamp contact area to reduce friction this will aid assembly e Insert the stud bolts into the bolt holes of the clamp ears Install the nuts ensuring that the spherical surfaces of the nuts and the clamp are in proper position for mating e Lubrication of the bolting and the spherical faces of the nuts and the clamp is recommended e Tighten the bolting in a criss cross pattern i e bolt 1 3 2 4 to keep the spacing between the clamp halves approximately equal e To properly preload the Grayloc connector against gasket loads fluid pressure loading thermal shock loading and normal pipe
11. t an effective seal The connector should not be tightened while under pressure loading or severe mechanical loads Do not weld on Grayloc clamps bolting or seal rings without consulting Grayloc Products All components of the Grayloc assembly should be obtained only from Grayloc Products or one of its authorized licensees Do not substitute non Grayloc brand parts in Grayloc connectors 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 5 and Section 4 7 for details 5 2 2 Yearly e Disassemble riser clean and degrease all components e Inspect the condition of all sealing surfaces and surface coatings OPS 3068 Rev C 7 User Manual z Fuel Grayloc Riser OIL TOOLS Re coat sealing surfaces if necessary If in doubt contact Phuel Oil Tools Ltd Regrease components Re assemble torque side outlet bolts to 7O6Nm 523 ft lb Pressure test to maximum working pressure in accordance to testing procedure see 6 Inspect paint work and repair as necessary Five Yearly Yearly Maintenance plus the following Carry out surface NDE on all component threads and damaged surfaces Pressure test to test pressure witnessed by certifying authority where applicable Repaint 5 3 Safety OPS 3068 Rev C Many of the components are heavy and should not be lifted without lift
12. ual A Phue Grayloc Riser OIL TOOLS 4 Operation All operations to be carried out by suitably qualified and competent personnel 4 1 Lifting End 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 Before Assembly e The Grayloc seal ring does not seat until the connection is fully tightened therefore a small clearance or standoff between the ring rib and hub face should be observed when the ring is placed into a mating hub If no standoff is present use a new seal ring e Clean all lubricants and foreign matter from the hub seating surfaces before installation Use a non abrasive material to clean the seal rings of all foreign matter Normally all seal rings have a coating or plating cadmium PTFE MoS2 which acts as a lubricant during make up In some applications where uncoated unplated seal rings are used a light film of clean lub

User Manual Grayloc Riser

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