Emerson Roxar 10000psi User Manual Download Page 10

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User Manual
Document no. / rev.: ROX000337352_AE

Hydraulic Retrieval Tool

Description

Size

Quantity

(pc)

Comments/ Applicable for

Spanner

26, 30, 32mm

Hydraulic sold/hollow plug.

Adjustable spanner

Small & Medium

Misc

Unbraco/Allen key kit

2.5-10 mm

kit

Misc

Unbraco/Allen key bits

6-10 mm

Kit

Misc

Ratchet

½” inch

Torque wrench

25-200Nm

Misc

Torque wrench

100-500 Nm

Misc

Hex socket

10 mm, 3/4in drive

Misc

Hex socket

17 mm, 3/4in drive

Misc

Hex socket

5 mm, screw key

Misc

Brass/Plastic hammer

Hammer nuts

Retainer ring pliers

Misc

Wrench

>105 mm

Hydraulic access fitting cover

Multipurpose lubrication

WD40, CRC 565 or similar

O-Ring grease

Grease/lubricant

Chesterton 785 or similar

Table 2: Tools list

Summary of Contents for Roxar 10000psi

Page 1: ...Document no rev ROX000337352 AE ttt USER MANUAL Roxar Hydraulic Retrieval Tool ...

Page 2: ...c Access Fitting 8 2 4 Air Hand pump 9 2 5 Tools list 9 3 OPERATION 11 3 1 Personnel qualifications 11 3 2 HSE 11 3 3 Preparations pre job 12 3 4 Access fitting Inspection Preparation 13 3 5 Online Retrieval of Device 14 3 6 Online Installation of Device 20 3 7 Troubleshooting Guide 23 3 8 Retrieval Checklist 25 4 Maintenance 29 4 1 Routine inspection before use 29 4 2 Routine Maintenace 30 4 3 Ma...

Page 3: ... competency and up front training needed to perform this work safely This user manual describes any work performed from a strictly general point of view so any particular application installation or process needs to be evaluated as specific cases and adapted to under the responsibility of the operator If there is any need for further clarifications please contact your regional Roxar Emerson repres...

Page 4: ...ontrol room that process changes which could vary system pressure such as surges caused by opening and closing of valves and chokes must be delayed until completion of retrieval operations 7 Prior to performing any retrievals ensure the pipeline pressure temperature and media are confirmed with facility operations personnel or control room 8 Ensure the relevant Material Safety Data Sheets for the ...

Page 5: ...om Web www emerson com Go to Roxar brand under Emerson Automation Solutions 1 6 Product support To ensure the optimal response regardless of time zones and to minimise downtime of the product Roxar Global Service Centre is organised through a network of service centres world wide Manned by skilled operators and engineers our Global Service Centre supports all your service requirements or technical...

Page 6: ...s for operation and maintenance are similar as for the double isolation Based on this the single isolation valve is not further described in this document Figure 1 Hydraulic retriever and service valve 2 1 Hydraulic Retriever The Double Acting Hydraulic Retriever is a tool designed for servicing all kinds of equipment that can be installed into the access fittings With the Double Acting Hydraulic ...

Page 7: ...User Manual Document no rev ROX000337352_AE Hydraulic Retrieval Tool 7 Figur 2 Hydraulic retriever main components ...

Page 8: ...ce valve consists of the following main components 1 End section 2 Main body upper section 3 Main body service valve 4 By pass valves 2x 5 Ball lever 2x 6 Bleed valve Internals isolation balls and seals are not shown 2 3 Hydraulic Access Fitting The Hydraulic Access Fitting has either a welded or flanged connection to the pipe and holds the plug and or any type of monitoring device A heavy duty co...

Page 9: ...the hydraulic pump is used to create a higher pressure inside the retriever than in the pipeline thereby pushing the monitoring equipment into the access fitting There are two types of hydraulic pumps Air driven pump dual port Manual pump dual port Figure 5 Hydraulic pump devices 2 5 Tools list The table below lists all the tools needed for operation and maintenance of the hydraulic retrieval tool...

Page 10: ...aco Allen key bits 6 10 mm Kit Misc Ratchet inch 1 Torque wrench 25 200Nm 1 Misc Torque wrench 100 500 Nm 1 Misc Hex socket 10 mm 3 4in drive 1 Misc Hex socket 17 mm 3 4in drive 1 Misc Hex socket 5 mm screw key 1 Misc Brass Plastic hammer 1 Hammer nuts Retainer ring pliers 1 Misc Wrench 105 mm 1 Hydraulic access fitting cover Multipurpose lubrication NA WD40 CRC 565 or similar O Ring grease NA Gre...

Page 11: ...his contact your local Roxar and Emerson representative 3 2 HSE 1 Roxar Online Hydraulic Retrieval Operations Risk Assessment must be used and followed in conjunction with this document when performing all online hydraulic retrieval operations 2 Two Roxar trained operators are required to perform online hydraulic retrieval operations at all times At least one of operators needs to be certified for...

Page 12: ...ever Tool involves bleeding off pressurized fluid gas from the pipe system If the pipe system contains hydrocarbons bleeding off liquid gas might trigger gas detectors hence such operations must always be clarified with the operators before the job starts 2 Have Job Safety Environment Analysis filled out and Work Permit Active before starting any work 3 Control room facility operators are to be no...

Page 13: ...ntly tightened 2 3 Screw out locking pins for inspection one at a time 2 4 Check the locking pin O rings for cuts and wear and replace if necessary If a locking pin s O rings are replaced change all O rings on the remaining locking pins with this fitting 2 5 Inspect the locking pin hole and clean if necessary especially the sealing surface where O rings seat 2 6 Use anti seize lubricant for the lo...

Page 14: ...access fitting where the O ring from the service valve will seat If any damage or pitting is noticed do not continue with this location Access fitting is damaged and will have to be changed out when the line is shut down 8 Inspect the O ring in the bottom end of the service valve Make sure O ring is installed If missing install new O ring 9 Mount the service valve on the access fitting Tighten it ...

Page 15: ...lve and mate the threads on the rod and the plug Screw the rod into the plug by rotating the retriever Screw until the rotation stops Do not tighten 17 Connect the hoses from the pump tighten safety nuts and set the pump to retrieve Open the head valve Hold the retrieval tool hammer nut away from the service valve threads Pump in retrieve mode until the retrieval tool is pulled towards the service...

Page 16: ...w Tighten the locking pins and then increase the pressure Loosen locking pins again Figure 3 Steps 20 22 21 Check to ensure that the service valve handles are fully open Also check that the bleed off valve on the retrieval tool is closed and that both by pass valves are closed on the service valve 22 Close head valve to keep the pressure within the retriever The locking pins should only be screwed...

Page 17: ...e the service valve If the valve cannot be closed the probe must be installed again and the valve inspected in order to determine the reason for this problem If the ball valve still cannot be closed it is most likely due to one of the following causes 26 1 There are large amounts of sand debris inside the valve hampering the rotation of the ball 26 2 The device is not fully retrieved 26 3 The devi...

Page 18: ...e must be reinstalled and the valve must be serviced If a double service valve is being used close the upper service valve ball Figure 5 Steps 25 28 29 If the service valve is sealing properly the retriever can be removed from the service valve Loosen the hammer nut and unscrew it from the valve This should be able to be done without any resistance between the valve and tool Then lift the retrieva...

Page 19: ...ure primary packing is replaced and correct version of wear rings are installed Change out wear rings if damaged Make sure the wear rings are of the new type with a minimum 5mm 1 4 gap to avoid the possibility of pressure building up The old type wear rings with no gap is never to be used or re used ...

Page 20: ...mer nut onto to the valve and tighten it 33 Set pump to install Make sure that the bleed valve on the tool is closed 34 If a double service valve is being used open the by pass valve for the upper ball closest to the retrieval tool and then open the ball itself 35 Open the by pass valve for the lower ball closest to the access fitting and then open the ball itself The pressure in the retriever wil...

Page 21: ...g afterwards Continuously monitor the pump pressure during the installation and do not exceed 100 bar over line pressure If the pump pressure increases from the line pressure earlier than expected stop immediately If this occurs close the service valve and slowly release the pump pressure See step 28 of this procedure to release the pressure in the retriever and remove the tool for inspection When...

Page 22: ...king pins and then retighten them If the leaks are still there the plug will have to be pulled for inspection Follow the same steps of this procedure as used before 44 Providing no leaks occur the retrieval tool can be removed Loosen the hammer nut and unscrew it completely from the service valve Be aware of fluid that might flow out when the retriever is being disconnected Set the pump to install...

Page 23: ...ation 1 If you feel a location may be damaged or could cause an issue during online retrieval operations make note of the findings issues notify the client that the location will require further investigation repair during a planned shutdown and move on to the next location 2 If leaks are discovered when removing the cover nut repeat steps 2 5 one more time If the leaks cannot be stopped then put ...

Page 24: ...f the pump To balance the pressures with the pump use the following steps a Set the pump to RETRIEVE and pump until the probe is fully retrieved b Install the Back Pressure Quick Coupling Assembly included in the retriever Kit on the Bleed off Valve c Disconnect the hose from the female quick coupling on the middle of the retriever and connect it to the Back Pressure Quick Coupling Assembly on the...

Page 25: ...ids available 6 Parts and equipment inspected Access fitting inspection Preparations YES NO N A 1 Confirm pipeline pressure and contents Pressure Contents 2 Checked pressure gauge on pressure proof cover if applicable a Is cover tightened b Inspect locking pins for damage Pin 1 damaged Pin 2 damaged Pin 3 damaged Pin 4 damaged c Do locking pin O rings need to be changed If answer is yes to any loc...

Page 26: ... Close head valve on retriever b Release pressure on the pump c Mount a quick connection nipple to the bleed off valve d Remove the hydraulic hose furthest away from the pipe from its normal position on the retriever and mount it on the bleed off valve e Open the bleed off valve and set the pump to install f Use the pump to fill the Retrieval tool cylinder and the service valve full with hydraulic...

Page 27: ...ill any remaining fluid 30 Pump set to install and the plug assembly has been pumped out of the retriever Correct guide wear rings mounted on the plug replace if wrong type or damaged Online installation of device YES NO N A 31 Plug assembly retrieved into the retriever do not fully retract the rod to the bottom of the retriever 32 Checked O ring in front of the retriever tool Mounted retrieval to...

Page 28: ...ammer nut unscrew it Set pump to install and pump out connecting rod until fully extended and pressure on pump is at least 50 bars Is the head valve on the retriever closed and the pressure in the pump is released 45 Disconnect hoses from retriever tool and unscrew the retrieval tool connecting rod from the plug Is the lower service valve ball closed to verify that the plug is fully installed 46 I...

Page 29: ... the bottom of the service valve and on the union thread adapter 3 Check that bypass valves and bleed valves are operating properly 4 For the service valve close and open both balls to verify functionality 5 Do a functional test of the hydraulic retriever to ensure that internal seals are undamaged and bleed valve is not obstructed Connect both hoses from the pump to the retriever Set the pump to ...

Page 30: ...re 6 Continue with operation or remove the tool 4 3 Maintenance when in use If the retriever and service valve is used on high pressure above 200bar gas systems pure or dissolved gas the O rings in both the retriever and the service valve shall be replaced after every 6th complete high pressure gas operation retrieval installation Only operations on gas above 200 bar shall be counted so if the ret...

Page 31: ...now be properly cleaned and inspected Use the wood stick rugs and lubrication cleaning solvent to clean the bores of outer and inner barrel After cleaning all surfaces should be lubricated with a multipurpose lubricant that also drives out moisture and protects against corrosion Assembly Assembly will be done in the reverse order of disassembly Additional key points for the assembly will be the fo...

Page 32: ...following instructions Disassembly and cleaning 1 Remove the handle 10 11 2 Loosen the eight bolts 18 and remove the end section 36 3 Rotate the stem of the upper ball section 1 to closed position and then remove the ball 5 Remove the ball seat 4 4 Remove the circlip ring 23 5 Remove stop ring 9 6 Push the stem 8 into the main body upper section 1 7 Repeat the steps 4 6 for the 2nd ball in main bo...

Page 33: ...retriever side of the service valve Hydraulic pump 4 5 Biennial Inspection It is advised that the retrieval tool and service valve gets a full inspection every second year according to Roxar procedures The tool will undergo a complete inspection with replacement of all seals and shell strength test together with fully functional test at maximum working pressure 4 6 Spare parts The following parts ...

Page 34: ... has been properly cleaned maintained and preserved it should be stored in the original transport cases in which it was delivered The cased should be dry and clean on the inside before the equipment is being place into them By pass valves and head valve shall be open The equipment shall be stored indoor in a dry area Maintenance during storage If the equipment has been properly preserved for stora...

Page 35: ...User Manual Document no rev ROX000337352_AE Hydraulic Retrieval Tool 35 Attachment 1 Hydraulic Retriever Tool ...

Page 36: ...User Manual Document no rev ROX000337352_AE Hydraulic Retrieval Tool 36 Attachment 2 Double Isolation Service Valve ...

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