Emerson Roxar, User Manual

Page 1: ...User Manual ROX000295904 Rev AC June 2020 Roxar Mechanical Retrieval Tool User Manual ...

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Page 3: ... retriever tool 10 2 3 Service valve 15 2 4 Hand pressure pump 19 Chapter 3 Preparation 21 3 1 Initial preparation 21 3 2 Tools and equipment 22 3 3 Consumables for operation 22 Chapter 4 Operating instructions 25 4 1 Retrieving a device 25 4 2 Installing a device 29 4 3 Troubleshooting guidelines 31 4 4 Qualification requirements and training programs for operators 32 Chapter 5 Maintenance 35 5 1...

Page 4: ...Contents User Manual June 2020 ROX000295904 4 www Emerson com Roxar ...

Page 5: ... contains safety and contact information for the user 2 Technical description provides more specific descriptions of the different product components This section explains the different measuring techniques together with recommendations for use of the different types of equipment It discusses the weight outline dimensions restrictions and information about how to order products 3 Preparation descr...

Page 6: ...tandards Z535 6 2011 R2017 DANGER Serious injury or death will occur if a hazardous situation is not avoided WARNING Serious injury or death could occur if a hazardous situation is not avoided CAUTION Minor or moderate injury will or could occur if a hazardous situation is not avoided NOTICE Data loss property damage hardware damage or software damage can occur if a situation is not avoided There ...

Page 7: ...ead understood and adhered to Ensure that any operator that is conducting work on the equipment is following end user guidelines on the use of protective equipment including but not limited to Safety helmet or hard hat Steel toed shoes Safety glasses Working gloves suitable for mechanical operations Chemical resistant latex gloves or the equivalent Long sleeved fire retardant shirt and fire retard...

Page 8: ...e certified for this work Emerson assumes no responsibility for incidents or consequences of incidents occurring as a result of the use of either mechanical or hydraulic retrieval tools by others than Emerson or its designated personnel and have no liability whatsoever for any such work Consult Emerson for more details on both training and certification 1 6 Warranty restrictions Visually inspect a...

Page 9: ...s and both injection and sampling equipment In addition the tool can also install and retrieve other devices that can be installed in Roxar mechanical 2 inch access fittings or mechanical 2 inch access fittings from other vendors that are compatible or interchangeable with Roxar 2 inch mechanical fittings on pressurized lines Figure 2 1 Service engineer manning a Roxar Mechanical Retriever Tool an...

Page 10: ...tion valve refer to the Roxar Service Valve Product Data Sheet 2 2 Mechanical retriever tool The Roxar Mechanical Retrieval Tool is based on a telescopic pressure balanced design This means that when a retrieval tool and service valve are installed on the access fitting the tool can be easily operated and telescoped freely even if it is exposed to pipe pressure Figure 2 3 Roxar Mechanical Retrieva...

Page 11: ...h pressure conditions while users can retrieve and install devices in the access fitting The telescopic operation refers to the expanding out and collapsing in the tool WARNING Risk to Personnel and Equipment If particles dirt or wax are present the pressure balance function described above may not provide satisfactory pressure balance in the mechanical retrieval tool and the pressure difference c...

Page 12: ... E Pressure gauge F Union thread adapter G Plug body H Plug pilot I Bleed valve J Hammer nut Specifications and dimensions The Roxar Mechanical Retrieval Tool can operate on pressurized lines and vessels up to 6 000 psi 420 bar and fluid temperatures up to 400 F 204 C The main dimensions and weights are displayed in Figure 2 5 and both Table 2 1 and Table 2 2 Technical description User Manual June...

Page 13: ...unting 300 mm B Mechanical Retrieval Tool C Mechanical Retrieval Tool length including the service valve D Service valve length 230 mm E Mechanical access fitting F Front view G Side view User Manual Technical description ROX000295904 June 2020 www Emerson com Roxar 13 ...

Page 14: ...9 5 34 40 45 5 Retriever kit approximate weight kg including the single valve 13 kg 65 67 69 71 75 81 87 Table 2 2 Mechanical retriever tool with a double service valve main dimensions and weight Maximum Device Length mm 150 240 350 425 640 920 1170 Mechanical Retrieval Tool length extended including the double valve C mm 1328 1508 1733 1878 2308 2868 3368 Removal clearance with the double valve C...

Page 15: ...of the balls and a separate bleed valve The Roxar Service Valve is compatible with 2 inch access fitting systems provided by most common corrosion monitoring Note A single isolation service valve is also available if required to use with the Roxar Mechanical Retrieval Tool Procedures for operation and maintenance are the same for both service valve versions The use of single isolation service valv...

Page 16: ...ouble Block Service Valve Figure 2 6 Double isolation service valve main components A Ball lever l B By pass valve 1 C By pass valve 2 D Main body service valve E End section F Main body upper section G Ball lever 2 Technical description User Manual June 2020 ROX000295904 16 www Emerson com Roxar ...

Page 17: ...F 204 C The double block isolation version weights 22kg while the single isolation weights 13kg Figure 2 7 Dimensions for the double block and bleed valve Note In Figure 2 8 the probe length varies depending on the customer s pipe size and the flow traveling through the pipe User Manual Technical description ROX000295904 June 2020 www Emerson com Roxar 17 ...

Page 18: ...al Retrieval Tool A Clearance for mounting 300 mm B Mechanical Retrieval Tool C Mechanical Retrieval Tool length including the service valve D Service valve length 230 mm E Mechanical access fitting Technical description User Manual June 2020 ROX000295904 18 www Emerson com Roxar ...

Page 19: ...he operator can face difficulties trying to achieve satisfactory pressure balance in the mechanical retrieval tool The pressure difference can force the mechanical tool to expand uncontrollably potentially causing harm to the operators Apply pressure above pipeline pressure to the tool by an external pump User Manual Technical description ROX000295904 June 2020 www Emerson com Roxar 19 ...

Page 20: ...Technical description User Manual June 2020 ROX000295904 20 www Emerson com Roxar ...

Page 21: ... and tools to verify that all parts are in perfect condition refer to Performing a routine inspection for further details Prior to performing any retrieval operations 1 Notify the control room 2 Advise that these process changes could affect system pressure 3 Surges to adjust system pressure such as the opening and closing of both valves and chokes must be delayed until retrieval operations are co...

Page 22: ... operation Retainer ring pliers 1 Required for assembly tool Pin hook wrench 6 mm tap 1 Mechanical covers and retriever union thread adapter Multipurpose lubrication 1 Multipurpose or marine lubricant Grease or lubricant 1 High temperature grease or lubricant Note Additional equipment may be required depending on facility requirements or the type of fluid in process for example a container to disc...

Page 23: ...gns of wear If a standard hollow plug is in use the probe packing must also be replaced whenever performing a retrieval operation Standard probe packing is made of PTFE but special materials may be applicable Always confirm with project documentation if a special material is applicable such as PEEK Figure 3 1 Mechanical plug design options A Position 1 B Position 2 C Position 3 Table 3 2 Part numb...

Page 24: ...ecommends having an operational seal kit available during service campaigns The operational kit consists of the o rings that seal the interfaces referenced previously Different materials are available depending on media type Part numbers are available as described in the following table Table 3 3 Part numbers for the seal operation kits Description Material Part number Operation seal kit VITON 75 ...

Page 25: ... is started Procedure 1 Remove the protective cover only if no leakage is visible If a pressure retaining cover is used make sure to do the following a Fully open the bleed plug b Allow for any pressure to bleed off c Close the bleed plug and wait 2 minutes d Repeat substep 1 a e If any leakage is detected do not remove the cover The measurement provided by the pressure gauge is only a indication ...

Page 26: ...unterclockwise slightly maximum inch turn to verify that it comes loose without using too much torque WARNING Risk to Personnel and Equipment Do not turn the plug more than an of an inch turn or corrosive gas or liquid could spill out and cause serious injury If a leak starts to occur retighten the plug until the leak stops 5 Inspect the o ring in the bottom of the service valve and verify that it...

Page 27: ...r nut out refer to the expanded retriever on the right of Figure 4 2 Ensure it turns smoothy without sticking or catching if the retriever does not turn smoothly it might require lubrication Note If the access fitting is mounted at the 12 o clock position consider using the safety clamp to avoid the retriever collapsing when mounted on the service valve For the 3 6 or 9 o clock positions the retri...

Page 28: ...ot hits the threads on the plug hexagon 12 Gently screw the retriever clockwise until the plug pilot is fully engaged with the plug The o ring on the plug pilot is there to avoid over tightening Do not exert too much force on the retriever because it can cause the pilot body to slide onto the plug hexagon 13 Push the retriever towards the fitting and rotate it slightly back and forth until the pil...

Page 29: ...essure on the retriever pressure gauge is similar to the pipe pressure e When balanced pressure is confirmed continue to unscrew the plug from the fitting 13 up to 15 turns 17 When the plug has been cleared from the threads fully expand the retriever to pull the device through the service valve and into the retriever If applicable mount the safety clamp 18 Close both balls in the service valve and...

Page 30: ...equalized open both balls on the service valve 7 If installed remove the safety clamp and in a rotating sliding movement collapse the retriever all the way until the plug stops at the access fitting NOTICE Be careful when entering the plug onto the access fitting so that the threads are not damaged 8 Tighten the plug for approximately 15 turns until it seats in the access fitting Then tighten the ...

Page 31: ... service valve leaks check if it is properly closed Also check that the by pass valves are closed If leaks in the valve cannot be stopped either the plug or the probe must be reinstalled and the service valve must be inspected for further repair if applicable 2 Inspect the o ring in the bottom of the service valve and verify that it is properly in place If necessary replace the o ring before proce...

Page 32: ...opening the service valve especially when the line pressure is high above 1 160 psi 80 bar The pressure should then be balanced by use of the external pump To balance the pressure with the pump use the following steps Recommended actions 1 Connect a pump or another sort of pressure vessel to the bleed off valve on the retriever Open the bleed valve and pressurize the retriever to a pressure equal ...

Page 33: ... use of either mechanical or hydraulic retrieval tools by others than Emerson or its designated personnel and have no liability whatsoever for any such work Consult Emerson for more details on both training and certification User Manual Operating instructions ROX000295904 June 2020 www Emerson com Roxar 33 ...

Page 34: ...Operating instructions User Manual June 2020 ROX000295904 34 www Emerson com Roxar ...

Page 35: ...perly cleaned and maintained after its last use If in doubt follow the maintenance instructions in Maintenance after use 5 1 1 Performing a routine inspection If the tool is to be used over a period of several days this check should be performed daily before the first retrieval operation is started Procedure 1 Inspect the different components and verify that all are clean and undamaged 2 Check tha...

Page 36: ...using the guidelines below Important To clean the barrels of the Roxar Mechanical Retrieval Tool use a clean straight nonmetallic pole made of wood nylon or a polymer with a smooth surface The pole should have an external diameter between 25 4 mm and 31 75 mm and a length that is equal to the length of the retriever when it is collapsed The cloth for cleaning the barrels should be clean and not co...

Page 37: ... Use the nonmetallic pole cloth and lubrication or 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 Mechanical retriever assembly Prerequisites A complete assembly drawing of the mechanical retriever tool can be found in Roxar Mechanical Retriever...

Page 38: ...n inside the valve around the ball to remove all deposits Then lubricate the ball with oil and check that it rotates properly before next use If this is not successful the valve must be disassembled and serviced as described below Before storage of the service valve it should be disassembled and cleaned properly as described in the following instructions Procedure 1 Remove the handle 32 2 Loosen t...

Page 39: ...performed in reverse order of disassembling the device Procedure 1 Attach the by pass valves to both by pass valve housings 18 and tighten 2 Attach and tighten the bleed valve 17 3 Push the stem 35 into the main body upper section 6 4 Attach the stop ring 29 5 Attach the circlip washer wave spring 6 Repeat the steps 5 7 for the 2nd ball in main body service valve 5 7 Attach the ball seat 2 and the...

Page 40: ... against corrosion Storing After the equipment has been properly cleaned maintained and preserved it should be stored in the original transport cases in which it was delivered These cases should be dry and clean on the inside before the equipment is placed into them Maintenance during storage If the equipment has been properly preserved for storage as described no additional maintenance during sto...

Page 41: ...nical Retriever VITON 75 ROX000296784 Kit includes positions 9 10 11 18 19 and 20 of Roxar Mechanical Retriever Assembly FR 25 90 ROX000314761 ELAST O LION 101 ROX000314762 Hammer nut repair kit VITON 75 ROX000322232 Kit includes positions 8 12 18 19 and 28 of Roxar Mechanical Retriever Assembly FR 25 90 ROX000322237 ELAST O LION 101 ROX000322239 Double ball service valve Table A 2 Spare part list...

Page 42: ...X000321615 ELAST O LION 101 ROX000321617 Miscellaneous spare parts Table A 3 Spare Parts List for Miscellaneous Items Description Material Part number Comments Tool Seal carrier remover 6K various ROX000322186 To either assemble or disassemble the service valve seal carrier Blind plate for service valve 6K various ROX000325301 Composed by blind plate equipped with the hammer nut pressure gauge and...

Page 43: ...B Attachments This section contains Roxar assembly drawings referenced throughout the document Roxar Mechanical Retriever Assembly User Manual Attachments ROX000295904 June 2020 www Emerson com Roxar 43 ...

Page 44: ...Double ball service valve assembly Attachments User Manual June 2020 ROX000295904 44 www Emerson com Roxar ...

Page 45: ...User Manual Attachments ROX000295904 June 2020 www Emerson com Roxar 45 ...

Page 46: ...ll other marks are property of their respective owners Roxar supplies this publication for informational purposes only While every effort has been made to ensure accuracy this publication is not intended to make performance claims or process recommendations Roxar does not warrant guarantee or assume any legal liability for the accuracy completeness timeliness reliability or usefulness of any infor...