Related Manuals for Emerson Roxar 6000 ps
Summary of Contents for Emerson Roxar 6000 ps
- Page 1 USER MANUAL Roxar Hydraulic Retrieval Tool Document no. / rev.: ROX000337352/AE...
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Page 2: Table Of Contents
User Manual Document no. / rev.: ROX000337352_AE Hydraulic Retrieval Tool TABLE OF CONTENTS: 1 1. Introduction ............................3 1.1 Disclaimer ..........................3 1.2 Purpose and scope ........................3 1.3 Warnings ........................... 3 1.4 Personnel safety and HSE ......................4 1.5 Operator training ........................ -
Page 3: Introduction
This document or any part of its content can not be reproduced or distributed in any way or means for any purpose without the written approval from Roxar Flow Measurements AS. The document is under Emerson Electric copyright protection ©2016 Emerson Electric Co. All rights reserved. 1.2 Purpose and scope Roxar provides safe and high quality products and services to meet the demands and requirements from our clients. -
Page 4: Personnel Safety And Hse
User Manual Document no. / rev.: ROX000337352_AE Hydraulic Retrieval Tool Personnel safety and HSE It's important that any recommendation or safety advice is followed to ensure safe operations. No deviation from this procedure is permitted without prior written authorization. 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. -
Page 5: Operator Training
4065 Stavanger, Norway E-mail: info.roxar@emerson.com 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. -
Page 6: Hrt System Components
User Manual Document no. / rev.: ROX000337352_AE Hydraulic Retrieval Tool 2. HRT SYSTEM COMPONENTS The hydraulic retrieval tool is together with the service valve used to replace different devices (probes, coupons, injection quills etc.) installed in traditional hydraulic access fittings during operation, meaning that piping and vessels are pressurized. - Page 7 User Manual Document no. / rev.: ROX000337352_AE Hydraulic Retrieval Tool Figur 2: Hydraulic retriever main components...
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Page 8: Service Valve
User Manual Document no. / rev.: ROX000337352_AE Hydraulic Retrieval Tool 2.2 Service Valve The service valve is a double isolating type, meaning that it has two balls that can be closed individually. The service valve also has by-pass valves for each of the balls and a separate bleed valve. Figure 3: Double isolating service valve The double isolation service valve consists of the following main components: 1. -
Page 9: Air / Hand Pump
User Manual Document no. / rev.: ROX000337352_AE Hydraulic Retrieval Tool Figure 4: Hydraulic access fitting assembly 2.4 Air / Hand pump When monitoring equipment is to be installed in an access fitting, 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. - Page 10 User Manual Document no. / rev.: ROX000337352_AE Hydraulic Retrieval Tool Quantity Description Size Comments/ Applicable for (pc) Hydraulic sold/hollow plug. Spanner 26, 30, 32mm Misc Adjustable spanner Small & Medium Unbraco/Allen key kit Misc 2.5-10 mm Unbraco/Allen key bits Misc 6-10 mm Ratchet ½”...
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Page 11: Operation
The other person needs as a minimum to have attended, and passed, a theoretical and practical training course for retrieval operators. For further questions to this, contact your local Roxar and Emerson representative. 3.2 HSE No deviation from this procedure is permitted without prior written authorization. -
Page 12: Preparations (Pre Job)
User Manual Document no. / rev.: ROX000337352_AE Hydraulic Retrieval Tool 8. Ensure the relevant Material Safety Data Sheets for the pipeline media are adhered to. 9. As a minimum the following PPE is required when performing hydraulic retrieval operations: h. Hard Hat Safety glasses Long sleeved fire-retardant shirt &... -
Page 13: Access Fitting Inspection & Preparation
User Manual Document no. / rev.: ROX000337352_AE Hydraulic Retrieval Tool Ensure that actual pipe pressure is confirmed before any operation is started A bleed off sequence might contain hot fluid or poisonous gas 3.4 Access fitting Inspection & Preparation 1. Check pipeline pressure and pipeline contents with an operator before operation begins. -
Page 14: Online Retrieval Of Device
User Manual Document no. / rev.: ROX000337352_AE Hydraulic Retrieval Tool 3.5 Online Retrieval of Device 4. Remove plug nut, or if a continuous monitoring cable is connected, remove the cable assembly from the fitting. 5. Remove the heavy duty protective cover. Check for leaks around the plug, and around the locking pins. - Page 15 User Manual Document no. / rev.: ROX000337352_AE Hydraulic Retrieval Tool 12. Set the pump to “install” and pump until the connecting rod is fully extended. Continue to pump until the pressure inside the retriever is a minimum of 50 bars and close the head valve watching the pressure gauge on the pump.
- Page 16 User Manual Document no. / rev.: ROX000337352_AE Hydraulic Retrieval Tool 20. Loosen all of the locking pins in the access fitting. The locking pins should only be screwed out until the head of the pin is flush with the outside of the access fitting. The locking pins should be easy to loosen.
- Page 17 User Manual Document no. / rev.: ROX000337352_AE Hydraulic Retrieval Tool 23. Switch pump from “install” to “retrieve”. 24. Slowly open the head valve to release the pressure. The connecting rod will start moving up into the tool (the line pressure will push it back), close the head valve and check for leaks (this is done to shorten the period / distance to pump the plug back in case of leaks).
- Page 18 User Manual Document no. / rev.: ROX000337352_AE Hydraulic Retrieval Tool 28. The pressure inside the retrieval tool must be released (contact control room and inhibit gas detectors in the area). Use the bleed-off valve on the retrieval tool. Have a bucket ready to catch the liquid that will come out.
- Page 19 User Manual Document no. / rev.: ROX000337352_AE Hydraulic Retrieval Tool serviced or replaced. Make sure 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.
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Page 20: Online Installation Of Device
User Manual Document no. / rev.: ROX000337352_AE Hydraulic Retrieval Tool 3.6 Online Installation of Device The installation procedure starts where the retrieval procedure ended, i.e. with a hydraulic access fitting on a pressurized line, without a plug inside, and with a closed service valve mounted onto the fitting to contain the line pressure. - Page 21 User Manual Document no. / rev.: ROX000337352_AE Hydraulic Retrieval Tool Disconnect the hose from the male quick coupling on “the top” (install) of “the retrieval tool and connect it to the back pressure quick coupling assembly on the bleed off valve. Ensure that the bleed valve is open.
- Page 22 User Manual Document no. / rev.: ROX000337352_AE Hydraulic Retrieval Tool 40. If primary packing has sealed and the pressure inside the tool has been bled off successfully, tighten all locking pins on the access fitting. The pins must be tightened evenly around the access fitting (in a cross pattern), in order to avoid the plug being pushed against one side of the fitting.
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Page 23: Troubleshooting Guide
User Manual Document no. / rev.: ROX000337352_AE Hydraulic Retrieval Tool 47. Clean the end of the plug, and especially the hole where the connecting rod was mounted. Remove all the dirt and moisture carefully. 48. Lubricate the end of the access fitting with anti-seize grease to prevent the sealing surface to be corroded etc. - Page 24 User Manual Document no. / rev.: ROX000337352_AE Hydraulic Retrieval Tool 4. Close only the lower ball (closest to the access fitting) at this stage. Use of force shall normally not be required for closing the valve. If the valve cannot be closed, it is most likely due to one of the following causes: a.
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Page 25: Retrieval Checklist
User Manual Document no. / rev.: ROX000337352_AE Hydraulic Retrieval Tool 3.8 Retrieval Checklist The following checklist may be used as a guideline of the operational procedure, as it indicates all the steps performed during the task. This checklist is NOT to be filled by the service technicians. It is rather a template for whomever wants to witness the task and to create awareness of all steps performed. - Page 26 User Manual Document no. / rev.: ROX000337352_AE Hydraulic Retrieval Tool 8. Is O-ring installed properly on the bottom of the service valve? (If Not Install new O-Ring) 9. Service Valve Mounted and tightened with plastic/brass hammer? Online retrieval of device 10.
- Page 27 User Manual Document no. / rev.: ROX000337352_AE Hydraulic Retrieval Tool 24. Slowly opened head valve to retrieve plug? Head valve closed to check for leaks? Reopened head valve? Pump in retrieve mode until pressure build up in the retriever? Checked for leaks around locking pins? Online retrieval of device 25.
- Page 28 User Manual Document no. / rev.: ROX000337352_AE Hydraulic Retrieval Tool 39. Close bleed-off valve and wait 1-2min. Verified that pressure is not building up in the retriever? (If build-up, stop here and go to troubleshooting guide. Note 8.) 40/41. Are locking pins tightened in a cross pattern in 3-4 turns? (If more or less turns, go to troubleshooting guide.
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Page 29: Maintenance
User Manual Document no. / rev.: ROX000337352_AE Hydraulic Retrieval Tool 4. MAINTENANCE Proper and regular maintenance is very important in order to ensure trouble free operation of the Hydraulic Retrieval Tool, and to keep it in good operating condition over a long period of time. For the Hydraulic Retreival Tool and the Service Valve, Roxar recommends complete maintenance and pressure test (1x design pressure) to be carried out every second year. -
Page 30: Routine Maintenace
User Manual Document no. / rev.: ROX000337352_AE Hydraulic Retrieval Tool If the pressure drops more than 20bar in any of the above described steps, the internal seals must be checked and replaced if necessary. Follow instruction in section 4.4.1 Hydraulic Retriever If the above points are inspected and no signs of damages, corrosion or missing functionality are discovered, the tool can be used. -
Page 31: Hydraulic Retriever
User Manual Document no. / rev.: ROX000337352_AE Hydraulic Retrieval Tool 4.4.1 Hydraulic Retriever With reference to retriever GA drawing in attachement 1. Disassembly and cleaning: Make sure all seals are installed at the correct position when reassembling the tool. If in doubt, check the GA drawing and measure the o-ring size. -
Page 32: Service Valve
User Manual Document no. / rev.: ROX000337352_AE Hydraulic Retrieval Tool 4.4.2 Service Valve With reference to service valve GA drawing in attachment 2. Maintenance of the service valve is basically determined by the environment in the process pipe. Presence of sand or other deposits will require frequent cleaning of the valve, maybe as often as after each retrieval / installation operation, while when used with “clean”... -
Page 33: Biennial Inspection
It is required to perform a pressure test after reassembly of a hydraulic retriever or a service valve. If the equipment is shipped from/to an Emerson workshop for the service assignment, the pressure tests can be performed at this workshop. -
Page 34: Storing And Preservation
User Manual Document no. / rev.: ROX000337352_AE Hydraulic Retrieval Tool 4.7 Storing and Preservation Preservation: If the retrieval tool and/or service valve is to be stored for a while after maintenance, the equipment should be preserved with a multipurpose lubricant. Make sure to select a type that also will drive out moisture and protect against corrosion. - Page 35 User Manual Document no. / rev.: ROX000337352_AE Hydraulic Retrieval Tool Attachment 1: Hydraulic Retriever Tool...
- Page 36 User Manual Document no. / rev.: ROX000337352_AE Hydraulic Retrieval Tool Attachment 2: Double Isolation Service Valve...