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Serial Number - Rohrback Cosasco Systems

1. 1 ee Ren nee TSW ame E 59wa43 OL01 0096 BJIABIS WWJIS ASSY A S ee a ee sus 2 pio 7 ES WIS NI E BAIA 404 wind 9NIY 40 08 59 0 2 o Way 901557 01535 00 09 LIN LIN WIE 80009 w 1 4 e 100109 LIM LIM MD Q ee was mamma WE aS IHC wv ve MS Ssrimwis IGN 5791 OE ___________ 21025 ars ary bv OSS ZO WHA SOWA OL IN BIVTAIVVN 921 NT 20 1509 2 3 RM gs20 92 oT 46 PONLE POSE DIRS TREN RSS o nai WTC at e Sr 35 36 SECTION 10 0 6000 PSISERVICE VALVE MAINTENANCE The maintenance interval required for the service valve will be determined by the media acting upon the valve Sand grit or metal chips may damage seats causing leaks which will require seat replacement Occasional lubrication will be necessary to reduce opening torque The use of a synthetic lubricant such as Rohrback Cosasco Systems 201688 18 recommended 101 Sour Gas Service On both the 3600 PSI and 6000 PSI service valves applicable materials comply with the requirements of NACE standard MRO175
2. 8L 9L 10L Connect the surge tube assembly Life the surge tube assembly and place the hammer nut end on the service valve Turn the hammer nut clockwise until the surge tube assembly s securely seated Use the brass hammer to tap a secure connection WEAR SAFETY GLASSES Close the surge tube bleed valve The same optional diverter hose assemblies used on the retriever and service valve are available for connection to the surge tube assembly For LOW PRESSURE lines pressures lower than 250 psi 17 BAR see L steps below For HIGH PRESSURE lines pressures higher than 250 psi 17 BAR see H steps below Open the service valve quickly Open the surge tube bleed valve and allow flow for approximately twenty seconds Close the surge tube bleed valve Close the service valve Open the surge tube bleed valve and allow the surge tube pressure to bleed off Close the surge tube valve Repeat steps 4L through 9L at least two more times 21 7 4 AH 6H 7H 8H 9H 10H 11 Open the service valve equalizing valve This will reduce the torque required to open the service valve Open the service valve quickly and then close the service valve equalizing valve Open the surge tube bleed valve and allow flow for approximately twenty seconds Close and open the surge tube bleed valve at least two more times and each time allow flow for approximately twenty seconds Each time the surge tube valve
3. valve body 20 Remove the bonnet to valve body o ring seal 11 which is now exposed 6 Remove the valve ball 19 from the valve body 20 37 10 3 10 11 Remove both the second seat seal ring 18 and its 17 from the service valve body 20 Remove the eight 5 8 Allen head cap screws 14 retaining the hammer nut adapter assembly 13 to the valve body 20 by using a 1 2 Allen wrench Remove the hammer nut adapter assembly 13 Remove the hammer nut to body retainer 15 from the valve body 20 Further disassembly of the stem 3 from the bonnet 7 previously removed in paragraph 5 is done by removing the stem seal 9 its back up ring 8 its o ring 11 and the thrust ring 10 which are now exposed Remove the by pass 21 and bleed valve 27 only if necessary for seal replacement To remove turn the large bleed screw retaining lock nut counterclockwise and completely disengage from the service valve body 20 To disassemble the bleed screw from its retaining lock nut it is necessary to remove the roll pin and the small nylock hex nut from the bleed screw top By turning clockwise on the bleed screw it will thread out through the bottom of its retaining lock nut Seal replacement can now be accomplished Service Valve Assembly 1 6 Clean all parts Examine all seals and o rings It is highly recommended that seals and o rings be replaced each time the servic
4. the retriever and if required install and tighten the wood clamp on the inner barrel Connect the retriever to the service valve First examine the o ring at the hammer nut end of the retriever for damage and replace if nicked cut or abraded Lift the retriever and place it on the service valve Turn the hammer nut clockwise until the retriever is securely seated on the service valve Use the brass hammer to tap a secure connection WEAR SAFETY GLASSES Ensure that the bleed valves are fully closed Even though the wood clamp may have been installed again ENSURE THAT THE RETRIEVER IS FULLY EXTENDED 13 11 12 Slowly open the service valve equalizing valve to pressurize the retriever Before proceeding further wait until the retriever 1s fully pressurized Open the service valve ball and close the equalizing valve Remove the wood clamp from the inner barrel and begin collapsing the retriever Use a twisting turning sliding motion Do this slowly until the plug assembly just barely contacts the access fitting body Engage the plug assembly to the access fitting body a When the plug assembly and the access fitting body are in contact slowly thread the plug assembly into the access fitting body by turning the retriever outer barrel clockwise and inward toward the access fitting body If the plug assembly does not start threading properly turn the retriever outer barrel counter clockwise one full turn
5. 10 is eased into position concentric with the o ring 11 Torque the four 7 16 Allen head cap screws 28 to 30 ft Ib and the two 1 2 Allen head cap screws 24 retaining the bonnet 2 to the valve body 1 to 50 ft Ib Use a 5 16 and 3 8 Allen wrench respectively 32 10 11 12 Install the position stop plate 25 over the top of the stem 3 and position the valve ball handle 5 onto the square head of the stem Ensure that handle positioning points away from the hammer nut end 20 when the valve ball 12 is in the open position Tighten the 5 16 Allen head cap screw 4 retaining the handle 5 to the stem 3 by using a 1 4 Allen wrench Torque the four 3 4 Allen head cap screws 14 that were initially installed as indicated in paragraph 4 to retain the hammer nut adapter assembly 20 and retainer 10 to 130 ft lb Install the by pass or vent valves 22 if they were removed for seal replacement Back off the bleed screws several turns before tightening the large bleed screw retaining lock nuts This avoids bottoming out the bleed screws on their seats before the retaining lock nuts are securely tight Check the service valve for smooth operation by opening and closing the ball 12 Pressure test the service valve Rated working pressure is 3600 psi 248 BAR at temperatures to 200 F 93 C 33 34 6 9 L 8 1 Biase SOT CION w 6001099 901000 COR 02 iain DO Oa
6. Open the bleed valve and drain the retriever product pressure and media residue into a container or safe area until all pressure has been relieved Disengage the socket adapter from the plug assembly Disconnect the diverter hose assembly if it was used Pull back the outer barrel slightly to disengage the socket adapter hex While maintaining this disengagement unscrew the socket adapter pilot from the plug assembly by turning counterclockwise five or six turns Loosen the retriever hammer nut and remove the retriever Using the brass hammer tap loose the hammer nut and unscrew fully WEAR SAFETY GLASSES Lift the retriever from the service valve do this carefully if the product media is a liquid because a small amount of product will be lost at the disconnect junction Install the stainless steel pipe plug Liberally grease 1 2 stainless steel pipe plug and install securely into the solid plug assembly NOTE Hollow plug assemblies use a red plastic pipe plug therefore greasing is unnecessary Orient the plug assembly The index mark filed as mentioned in paragraph 1 d must now be aligned to the product flow direction Turn the plug assembly hex clockwise until the mark aligns with the flow direction Ifthe plug assembly was installed as described sufficient room for travel to allow orienting will be available CAUTION DO NOT TURN THE PLUG ASSEMBLY HEX COUNTERCLOCKWISE TO ACHIEVE ORIENTATION 5 18 Prior to insta
7. assembly 4 or 33 can be removed by unscrewing it from the valve body The seals on the bleed valve can also be removed for servicing Retriever Assembly Durmg assembly the working surfaces of the retriever should be inspected for damage Should the chrome surfaces become damaged to the point that it no longer seals the parts will require replacement 1 Clean the outer barrel 20 inside surface using a cleaning solvent Wipe the bore thoroughly clean and inspect it for damage 27 6 Replace the o rings back up rings and seals each time the retriever is reassembled Apply grease to about four inches of the bore of the outer barrel 20 The grease will be filmed throughout the inside of the retriever when it 1s fully assembled and later stroked Clean the inner barrel 22 using solvent If the unplated areas of the inner barrel have been scratched or scored polish the area with fine emery cloth Minor scratches in the chrome can be dressed with fine crocus cloth Examine the inner barrel 22 threads and repair as necessary Lubricate mandrel seal 16 P N 201927 Press mandrel seal 16 cup facing outward into seal mandrel retainer 27 P N 208463 using care not to kink crimp or roll the seal Lubricate and install the o ring 30 P N 129398 into the o ring groove of the mandrel seal retainer 27 Install the mandrel seal retainer assembly into the inner barrel 22 cup fac ng inward Lubricat
8. at this stage Partially assemble the bonnet 7 by installing back up ring 8 insert stem seal 9 and o ring seal 11 in the bonnet 7 Install the thrust washer 10 on to the stem 3 in bonnet 7 Position the bonnet and stem into the valve body 20 stem recess Carefully position the bonnet 7 onto the valve body 20 ensuring that the thrust washer 10 is eased into position concentric with the o ring 11 Torque the six 1 2 Allen head cap screws 22 23 retaining the bonnet 7 to the valve body by using a 3 8 Allen wrench to 50 ft Ib Install the position stop plate 5 over the top of the stem 3 and position the valve ball handle 2 onto the square head of the stem 3 Ensure that handle positioning points are away from the hammer nut end when the valve ball is in the open position Tighten the 3 8 Allen head cap screw retaining the handle 2 to the stem 3 by using a 5 16 Allen wrench Torque the eight 5 8 Allen head cap screws 14 that were initially installed as indicated in paragraph 8 to retain the bleed adapter end plate 24 to 90 ft Ib Install the by pass 21 or vent valve 27 1f 1t was removed for seal replacement Back off the bleed screw several turns before tightening the large bleed screw retaining lock nut This avoids bottoming out the bleed screw on its seat before the retaining lock nut is securely tight Check the service valve for smooth operation by opening and closing the
9. ensure it 1s lubricated and operating properly If the retriever does bind or has a scratchy feel it may need lubrication See Section 8 Retriever Maintenance b Extend the retriever If the access fitting to be serviced is mounted on the top of line install the wood clamp on the inner barrel to prevent the retriever outer barrel from collaps ng of ts own weight To connect retriever Lift the retriever and place it on the service valve Turn the hammer nut clockwise until the retriever is seated on the service valve Retriever stroke length weights are as follows RBSA 14 38 165 17 25 kg 18 43 lbs 19 50 kg RBSA 25 48 lbs 21 75 kg RBSA 37 59 Ibs 26 25 kg RBSA 49 70 Ibs 31 75 kg 61 81 lbs 36 75 kg RBS 14 48 lbs 21 75 kg RBS 18 56 lbs 25 50 kg RBS 25 64 lbs 29 00 kg RBS 37 81 lbs 36 75 kg RBS 49 98 lbs 44 50 kg RBS 61 115 Ibs 45 25 kg 11 13 14 Tap the hammer nut tight Using a brass hammer WEAR SAFETY GLASSES Connect the socket adapter pilot Remove the wood clamp if installed Collapse or move the outer barrel toward the access fitting body until the socket adapter pilot contacts the plug assembly do not allow the socket adapter hex to engage the plug assembly hex A turning sliding motion as opposed to a straight sliding motion will prevent linear scratches on the barrels should san
10. is disassembled and reassembled Even then prior to assembly they should be thoroughly inspected for nicks cuts or abrasions Install the carrier seal 14 one of the two set seal rings 15 and its carrier 18 into the service valve body 1 NOTE There are two seat seal rings 15 and carriers 13 5 and that they are interchangeable Ifthe seats 15 are not being replaced install the better of the two seats 15 in the acme threaded end of the service valve Grease the face of the seat seal ring 15 Grease the valve ball 12 and install the better side in the acme threaded end of the valve body Install the other seat seal ring 15 and carrier 18 into the valve body 1 and in firm contact with the valve ball 12 Lubricate the swivel on the hammer nut adapter assembly 20 Install the retainer to valve body o ring 17 and retainer to access fitting body o ring 18 on the retainer 16 Assemble the hammer nut adapter assembly 20 and retainer 16 onto the valve body 1 with the four 3 4 Allen head cap screws 19 using a 5 8 Allen wrench DO NOT tighten them securely at this stage Partially assemble the bonnet by installing the back up ring 8 and stem seal 9 in the bonnet 2 Install the thrust washer 10 and stem 3 in the bonnet 2 Position the bonnet to valve body o ring 11 in the valve body 1 stem recess Carefully position the bonnet 2 onto the valve body 1 ensuring that the thrust washer
11. retainer 28 P N 208464 With the inner diameter groove facing the previously installed outer seal slide the partially assembled outer seal retainer 28 over the threads and into the thread relief of the inner barrel 22 Gently press the outer seal 18 into the groove in the seal retainer 28 Slide the assembled seal retainer onto the chrome surface on the inner barrel 22 Care must be used when moving the assembled seal retainer out of the thread relief groove to avoid twisting or kinking the outer seal 18 A good technique is to slide one side of the assembled retainer assembly from the thread relief groove onto the chrome surface and then press inward on the assembly to allow the opposite side to be slid onto the chrome surface Once the retainer assembly is on the chrome surface then slide the 28 10 11 12 14 16 17 18 19 20 21 assembled seal retainer into the outer barrel 20 Install the seal back up ring 21 P N 127541 behind the seal retainer assembly then install the seal stop collar 9 P N 127524 using four 3 8 Allen head cap screw 1 P N 116209 DO NOT tighten the screws fully at this time allow the seal stop collar to have slight play Grease and install the o ring 2 on the thread adapter 8 Install the back up ring 3 behind the o ring 2 and on the same side as the threads Slide the retaining hammer nut 7 and the retaining lock ring 18 onto the inner bar
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13. EPLACEMENT AS PROVIDED ABOVE IN NO EVENT WILL RCS BE LIABLE TO YOU FOR ANY DAMAGES WHETHER BASED UPON BREACH OF WARRANTY BREACH OF CONTRACT NEGLIGENCE STRICT TORT OR ANY OTHER LEGAL THEORY INCLUDING ANY LOST PROFITS LOST SAVINGS OR REVENUE LOSS OF USE OF THE PRODUCT OR ANY ASSOCIATED EQUIPMENT LOSS OF SUBSTITUTE EQUIPMENT OR OTHER INCIDENTAL OR CONSEQUENTIAL DAMAGES ARISING OUT OF THE USE OF OR INABILITY TO USE SUCH PRODUCT EVEN IF RCS OR AN AUTHORIZED RCS DISTRIBUTOR HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES OR FOR ANY CLAIM BY ANY OTHER PARTY INCLUDING CUSTOMERS OF THE ORIGINAL USER Any action for breach of warranty must be commenced with three 3 months of the expiration of the warranty period To obtain Limited Warranty Service or other assistance contact your nearest RCS office or distributor or contact RCS Customer Service directly at Rohrback Cosasco Systems Inc Tel 302 34 2 0 aa 11841 East Smith Avenue Fax NA Santa Fe Springs CA 90670 Ti 09 8 USA C WP50 RSO WARRANTY 43 44 41908 SONIEES 33 VLNYS SNILSAS 025 509 XJVBSHOU N3LNO 3S YNN MINED SNOISIA38 5 57654 357340 22821 N d 135 HON44M O6P9ZI N d W3S UJAJIHLJH vSGU SBU ZCZOLZ N d UJAJIHLIH YSBN SBU SCZOL N d 9 1001 30435 JHNSSJUd A0VB GGOCOZ N d 713
14. OS ATOMISSV ISOH AILNIA0 GBOPZI 713 Z AIBN3SSV 3SOH U3LU3N0 ICGPZE ka LY 0L XIBNJSSY ISOH UJLHJN0 609PZL ATGWISSY J08NS Z ASZI H19N37 43080 a0 SHJAJNIIU 804 SLAVA 45 ONY SNONdO Ct 1 XXXX 010009 SYIHLO TW NO OZ 3SN H3 UOHS YO S3HONI SHJAJNIJA VSAM NO E Nail ISN G 8 8 nonas Y X CZ RE 0009 a sima 2 OD 29 ET H USE N A ERA 50395 ISMYIHIO 553 SION LX 834308139 Ni GISWHOMNd 38 ATBWISSYV HAAJWIJA 1 442012 1V3S aczorz 9CZOLZ Ni St NMOHS LON 5 HIONTI 3080 OdaNiixa wa 04 HIONIT 83080 GiSdrnod 9 XXXX JI nal ISN SEY XXXX 31 MAU 350 9 81 14 Sr OL 3N0H0L 192 9 5 SOYJUHL OL 310 4d0X Alddv 2 14 OL 3NOHOL ONY ir2 dnS OL 310 Adv 8 87 HONI 08 OL JNOHOL 2192 4 5 SOVIHHL OL ALOX Ud0X Alddv 6 SNOMOBNNOD NO Advi OD 91 HONI OZ OL 3NOYOL 5 OL 3103 840 Alddy 1 AIBMISSW OL 121 975 LOL HUM SJOVAWNS WIS TW 2 y GO DER Zar 338 A 14 AS ZY Qu 2
15. Serial Number Part Number MODEL RBS RBSA RETRIEVER AND SERVICE VALVE USER MANUAL ROHRBACK COSASCO SYSTEMS INC 11841 E Smith Avenue Santa Fe Springs CA 90670 Phone 1 562 949 0123 Fax 1 562 949 3065 E mail rcs rohrbackcosasco com Web Site http www rohrbackcosasco com 600000 MANUAL REV E Section 1 0 2 0 3 0 4 0 6 0 7 0 8 0 9 0 10 0 TABLE OF CONTENTS Contents INTRODUCTION SAFETY CHECKLIST RETRIEVER amp SERVICE VALVE CONSTRUCTION amp OPERATION RETRIEVAL OF SOLID OR HOLLOW PLUG ASSEMBLIES INSTALLATION OF SOLID OR HOLLOW PLUG ASSEMBLIES UNDER PRESSURE RETRIEVER BACK PRESSURING RETRIEVER amp SERVICE VALVE SPECIAL TOOLS RETRIEVER MAINTENANCE 3600 PSI SERVICE VALVE MAINTENANCE 6000 PSI SERVICE VALVE MAINTENANCE 81 97 u SECTION 1 0 INTRODUCTION The COSASCO 2 RBSA and RBS retrievers and service valves are designed to install and retrieve the COSASCO 2 corrosion monitoring assemblies safely without shutdown and under pressure Both RBSA and RBS retrievers have features to permit easy handling and a single retriever and service valve can service any number of COSASCO access fitting monitoring points The retrievers incorporate a manifold with a bleed valve and a pressure gauge to allow the operator to monitor the internal pressure during use An optional diverter hose assembly can be attached by quick connect to the retriever manifold or service
16. Sulfide Stress Cracking Resistant Metallic Materials for Oil Field Equipment As stated in this standard Materials are resistant to but not necessarily immune to sulfide stress cracking under all service conditions Thus when the valve is used in sour environments it must be thoroughly cleaned after use to help prevent corrosion and or damage to internal materials 10 2 Service Valve Disassembly Applicable to 6000 pound service valve kit P N 210262 valve P N 210257 The RBS 6000 Service Valve has a valve ball that is removable only from the service valve hammer nut end access fitting body connection Normally for routine maintenance disassembly instructions indicated n paragraphs 8 and 9 need not be done 1 Loosen and remove the eight 5 8 Allen head cap screws 14 at the acme thread end using a 1 2 Allen wrench 2 Remove the bleed adapter end plate 24 from the valve body 20 exposing the first of two seat seal rings 18 and their carriers 17 Remove the seat seal ring 18 and its carrier 17 from the valve body 20 3 Remove the 3 8 Allen head cap screw 4 securing the valve handle 2 to the square head of the stem 3 by using a 5 16 Allen wrench Remove the position stop plate 5 which is now exposed 4 Remove the six 1 2 Allen head cap screws retaining the bonnet 7 to the valve body 20 by using a 3 8 Allen wrench Remove the bonnet and stem 8 and 7 intact from
17. air thread damage 1 Attach and grease the tap Attach the tool to the socket adapter pilot male thread Apply grease liberally to the cutting edges 2 6 Connect the retriever Extend the retriever fully Ifthe access fitting to be serviced is mounted on the top of line install the wood clamp on the inner barrel to prevent the retriever out barrel from collapsing of 1ts own weight Lift the retriever and place it on the service valve Turn the hammer nut clockwise until the retriever is securely seated and tightened in place on the service valve Use the brass hammer to make up a secure connection WEAR SAFETY GLASSES Open the service valve equalizing screw and then open the service valve ball Collapse the retriever with a twisting turning sliding motion on the retriever outer barrel until the tool just barely contacts the access fitting body Turn the retriever outer barrel two full turns counterclockwise This will help to allow the tap threads to align with the access fitting body threads For thread tap cutting slowly turn the retriever outer barrel clockwise allowing the tool threads to engage the access fitting body threads Continue turning the retriever outer barrel 14 to 17 turns occasionally turn the retriever outer barrel counterclockwise to help the tap threads to clear Do not allow the tap to bottom When the tap operation s completed connect the diverter hose assembly to the retriever bleed valve Ope
18. ature of 400 F 204 0 RBS retrievers feature a stainless steel outer barrel Viton o rings Teflon back up rings and graphite impregnated Teflon dynamic seals They are pressure rated to 6000 psi 414 BAR and have a maximum operating temperature of 400 F 204 O On both models a socket adapter assembly attached to the mandrel rod is used to install or retrieve the plug from the access fitting assembly The thread adapter on the inner barrel of the retriever connects directly to the outlet side of the service valves Two valves are available The standard valve is rated at 3600 psi 248 BAR and the high pressure valve is rated at 6000 psi 413 BAR Both valves have a maximum operating temperature of 250 Their selection depends on the maximum working pressure required The service valves incorporate two needle valves the first allows slow pressurizing of the retriever which reduces the torque required to open the service valve ball The second allows product bleed off through a special port either with or without the optional diverter hose assembly The valves comply with API Fire Sate Standard RPOF When the fittings are mounted at bottom of line they collect sand scale or other debris These particles can damage the threads of the access fittings as well as the working surfaces of the retriever and service valve Therefore extra care and maintenance should be given to equipment used in servicing any bottom mounted fitting Spec
19. ball Pressure test the service valve Rated working pressure is 6000 PSI 413 BAR at temperatures to 200 F 93 C 39 27 26 25 24 28 22 21 20 19 18 17 16 15 14 13 12 FIGURE 10 1 RBS 6000 SERVICE VALVE Bleed Valve O ring Bleed Adapter to Valve Body O ring Bleed Adapter to Valve Ball Carrier Plate Bleed Adapter End Screw Allen Head Cap 1 2 Screw Allen Head Cap 1 2 Valve By pass Body Valve Ball Ring Seat Seal Carrier Ball O ring Retainer to Body Retainer Hammer Nut to Body Screw Allen Socket Head Cap 5 8 Nut Hammer O Ring Hammer Nut Seal O ring O ring Bonnet to Valve Body Ring Thrust Seal Stem Back up Ring Stem Bonnet Plug Pipe Plate Position Stop Screw Allen Head Cap 3 8 Stem Handle Valve Ball Control Handle Extension Not Shown 40 l each l each l each l each l each 2 each l each l each l each l each 2 each 2 each l each l each 16 each l each 5 each l each l each l each l each l each l each l each l each l each l each FIGURE 10 1 RBS SERVICE VALVE 4 2 fred 5 Y Pa f 13 gt a a D a JU ET y Ik re NNN DOS oh NU SAR Z 4 gt y RV e NY m ESAS 2 OA Na ME ER EN IRA AR E 28 2 oa 1 NOT SHOWN BLEEDERS ARE SHOWN ROTATED AT 900 ANGLE FROM HORIZONTAL 42 LIMITED WARRANTY Rohrback Cosasco Systems I
20. base This may be due to improper weld procedures or noncentricity of access fitting body with the cut or hot tapped hole into the pipe This condition will require the reaming of the hole into the pipe with a hot tap square end mill part number 612016 7 12 14 5 13 5 16 f Incorrect access fitting body weld procedures This can cause body distortion or warpage due to excessive heat or improper after weld stress relieving If distortion or warpage appears minor the use of access fitting body seat reamer 125125 is recommended If distortion or warpage is major a new access fitting body should be welded to the line using the proper welding procedures See Manual M 1 300 Trepanning Positioning and Welding Procedures Indications of any of the above causes will be noted after retriever bleed off is accomplished as described in paragraph 13 The indications may be an unstable pressure gauge reading the hearing of pressure still entering the retriever or feeling the lack of pressure load on the seals as evidenced by a lack of friction If the plug assembly cannot be seated and sealed it may be necessary to leave the service valve on the line until a later shut down when repairs can be made If this becomes necessary a service valve blanking plug 127391 should be placed on the service valve after the retriever has been removed to prevent possible leaks or inadvertent opening of the service valve Retriever bleed off
21. be serviced s mounted on the top of line install the wood clamp on the inner barrel to prevent the retriever outer barrel from collapsing of 1ts own weight Turn the hammer nut clockwise until the retriever s securely seated on the service valve Use the brass hammer to tap a secure connection WEAR SAFETY GLASSES Open the service valve equalizing valve and then open the service valve ball Collapse the retriever remove the clamp and with a twisting turning sliding motion on the retriever outer barrel until the thread brush just barely contacts the access fitting body Brush the threads Continue the twisting turning sliding motion of the brush in a clockwise direction until it bottoms Retrieve the thread brush assembly Beginning with a very slight clockwise rotation pull the brush straight up and out of the access fitting body 10 Extend the retriever Close the service valve and the service valve equal z ng valve Bleed and remove the retriever Open the retriever bleed valve and allow pressure to bleed off completely Using the brass hammer tap loose and fully unscrew the retriever hammer nut WEAR SAFETY GLASSES Lift the retriever from the service valve Remove the thread brush assembly Unscrew the thread brush assembly from the socket adapter pilot Surge Tube Assembly 123672 The surge tube assembly s used to flush debris from the access fitting body by using line pressure 1 AL 6L 7L
22. by either the RBSA or RBS retriever will vary depending upon the service to which it is subjected Certain fluids will wash out all lubricant from the retriever after one retrieval others will deposit debris in the retriever making operation difficult If the retriever has been in use and it 1s anticipated not being used again for a period longer than one day 1t should be completely disassembled cleaned and lubricated Also f in a days operation because of adverse retrieval environment conditions the retriever becomes difficult to operate feels gritty and does not stroke or turn easily it should first be cleaned and lubricated without disassembly as indicated in Part 8 2 below If cleaning and lubricating without disassembly does not relieve the difficulties in the retriever operation 1t should be completely disassembled cleaned and lubricated as indicated in either Part 8 3 or 8 4 of this Section Lubricant choices are many For a particular service some experimentation may be necessary Recommended lubricants are 1 Motor Oil SAE 30 weight or equivalent 2 Lubriplate multi purpose A lithium base grease usually the best choice for most service since it is thin and applies easily Use for service temperatures of 0 to 350 F 18 to 177 C Available as COSASCO 129372 3 Synthetic lubricant A molybdenum disulfide grease containing rust and oxidation inhibitors It is recommended for use in extreme pressures and tempe
23. ch 15 enough to overcome seal friction and the weight of the outer barrel 6 SECTION 4 0 RETRIEVAL OF SOLID OR HOLLOW PLUG ASSEMBLIES The following procedure is for retrieval of solid or hollow plugs from access fitting bodies under pressure The operator should first determine pressure temperature and the type of media Any action which could vary pressure such as surges caused by the opening or closing of valves or chokes should be delayed until after the retrieving operation has been completed 1 Stroke and circumferential clearance Determine if the retriever has an adequate stroke clearance and that the entire operation has adequate circumferential clearance a Clearance beyond the top of the access fitting body s required for installation and extension of the retriever and service valve The following recommendations should give adequate clearance 14 stroke 5 feet 1 5 meters 18 stroke 6 feet 1 8 meters 95 stroke 7 feet 2 1 meters 37 stroke 2 9 feet 2 7 meters 49 stroke 11 feet 3 4 meters 61 stroke 13 feet 4 0 meters b In addition circumferential to allow movement of the operator s and free movement of the equipment is required The following recommendations should give adequate clearance Above ground level From the center line of the access fitting a rad us of at least three feet should be maintained Below ground level A minimum diameter culvert of manhole of fo
24. d or grit be present Turn the outer barrel clockwise about four turns to engage the socket adapter pilot threads to the female threads of the plug assembly Close bleed valves Ensure that both the retriever and service bleed valves are closed Connect the socket adapter hex Collapse the retriever outer barrel toward the access fitting body while turning slightly clockwise untl the socket adapter hex slides over the plug assembly hex a movement of about 5 8 16 mm Ifa bottom of line location is being serviced the retriever out barrel must be held manually in this position until plug assembly is disengaged from the access fitting body Retriever pressure balancing a Turn the retriever outer barrel slowly counterclockwise using the handles or head bar to unseat and begin backing off the plug assembly b Retriever pressurization will begin after 1 2 to 2 turns of the outer barrel Pressurization will be signified by one of three means gauge hearing the fluid enter the retriever or feeling the increase in friction as the seals experience pressure load When the retriever begins to pressurize stop turning the out barrel and wait for the retriever to pressure balance This is achieved only when the entire retriever and the operating line are at equal pressure If the retriever fails to pressurize after 2 turns back off the plug assembly by an additional 2 counterclockwise turns of the outer barrel If the retrieve
25. e inner seal 17 P N 201929 Press inner seal 17 cup fac ng outward into inner seal retainer 29 P N 208465 using care not to damage the seal Lubricate and install the o ring 32 P N 201926 into the o ring groove of the inner seal retainer Install the inner seal retainer assembly onto the inner barrel cup facing inward Insert the four 1 4 socket head cap screws 19 through the end cap screw holes and torque to 80 in lbs Apply grease to the inside and outside surfaces of the inner barrel 22 Stand the outer barrel 20 vertically with the bleed valve assembly end down Place the inner barrel 22 thread end first into the outer barrel 20 Hold the inner barrel 22 within the outer barrel and turn the barrels end for end Place a rag under the inner barrel 22 head end and push down on the outer barrel 20 until the barrels are n place Slide the seal installation tool P N 210473 over threads of inner barrel 22 and remove the seal push ring from the seal installation tool If tool s not available wrap threads with Teflon tape to protect the outer seal 18 from damage Lubricate outer seal 18 P N 201928 and slide the seal onto the inner barrel 22 with the cup facing the threads Work the seal carefully over the threads until it is resting in the thread relief groove of the inner barrel 22 between the threads and the chrome surface Lubricate and install the o ring 31 P N 201925 onto the outer seal
26. e valve is disassembled and reassembled Even then prior to assembly they should be thoroughly inspected for nicks cuts or abrasions Lubricate the swivel on the hammer nut adapter assembly 13 Install the hammer nut seal adapter to access fitting body o ring 12 in the hammer nut to body retainer 15 Install the retainer to body o ring 16 in the enclosed end of the valve body 20 Install the seal adapter plate 15 and the hammer nut adapter assembly 13 to the valve body 20 using 5 8 Allen head cap screws 14 Use a 1 2 Allen wrench and torque to 90 ft Ib Install one of the two seat seal rings 18 and its carrier 17 into the valve body 20 NOTE There are two seat seal rings and 2 carriers and they are interchangeable If the seats are not being replaced install the better of the two seats in the acme threaded end of the valve Grease the face of the seat seal ring 18 Grease the valve ball 19 and install the better side in the acme threaded end of the valve body 20 Install the other seat seal ring 18 and carrier 17 into the valve body 20 and in firm contact with the valve ball 19 38 10 11 12 14 16 Install the bleed adapter to valve body o rings 25 and 26 the bleed adapter end plate 24 Install the bleed adapter end plate 24 onto the valve body 20 using the 5 8 Allen head cap screws 14 by using a 1 2 Allen wrench DO NOT tighten them securely
27. g a crescent wrench to turn the pipe plug slightly counterclockwise If for any reason there 15 pressure behind the plug which after one or two minutes has not been bled off loosen the steel pipe plug 1 8 turn more If pressure bleeds off remove the pipe plug if it has not re tighten the prpe plug and refer to Section 7 Retriever and Service Valve Special Tools Section 7 4 The hollow plug assembly uses a plastic pipe plug as a dust cover only therefore no bleed off will be required Check the service valve Inspect the o ring at the hammer nut end for nicks cuts and abrading It is recommended to inspect and pressure test the service valve periodically to be sure it 1s in good working order as there is a possibility that should a problem occur it will have to be left on the line Connect the service valve to the fitting Lift the service valve assembly and place it on the access fitting body Thread the hammer nut clockwise until the service valve 15 securely seated Tap the hammer nut tight using a brass hammer WEAR SAFETY GLASSES Close and open the service valve ball to be sure there 1s adequate handle clearance If there is not loosen and reposition the handle until adequate clearance 1s obtained The valve should be left in the open position 10 Check the retriever Inspect the thread adapter o ring for nicks cuts and abrading a Stroke the retriever Extend and collapse the retriever to
28. g thread files or for more severe damage the thread die assembly part number 125112 can be used A spare access fitting body can be used to check for fit b Replace all o rings and packings If the plug assembly was previously used it is recommended that the seals be replaced Connect the corrosion monitoring or preventing device to the plug assembly After initial packing contact compress the packing by tightening the device up to 1 4 turn more Securely lock into place by tightening the set screw d Index the plug assembly hex If the corrosion monitoring or preventing device requires orienting with the product flow index the plug assembly by filing a notch across the top of the hex The notch should be filed so that the device can be aligned with the product flow Clean the fitting threads if required Thread condition can be assessed by the ease of the removal procedure If repair and or cleaning appears necessary see Section 7 Retriever and Service Valve Special Tools Connect the plug assembly to socket adapter pilot Engage the plug assembly female threads to the socket adapter pilot male threads Do not bottom the plug assembly on the socket adapter pilot but allow approximately 1 4 turn back off from full engagement the o ring on the socket adapter pilot should provide the proper spacing when hand tight Align the hex on the plug assembly with the hex on the socket adapter to ensure they will engage Extend
29. ial tools are available to aid in these situations See Section 7 Retriever and Service Valve Special Tools which describe the tools available to remove or flush sand scale hot tap chips or other debris from the access fitting If product and operating pressure permit lower than 2500 PSI 172 BAR the RBSA retriever with its thinner stainless steel outer barrel should be considered to reduce the weight The retriever has four main parts 1 The outer barrel 2 The mandrel 3 The socket adapter assembly 4 The inner barrel with thread adapter attached The outer barrel is rigidly connected to the mandrel rod By turning or sliding the outer barrel the movement is imparted to the mandrel rod The service valve has three main parts 1 The service valve body 2 The ball and seals 3 The bypass and bleed valve The COSASCO access fitting body and plug assembly hollow or solid form a seal However the design allows the system pressure to bypass the seal when the plug assembly is backed off one or two turns The bypass pressure enters the retriever through the service valve The system pressure exerts a load on the mandrel rod pushing out which is countered by an opposing equal load on the outer barrel pushing in Controlled pressurization of the retriever reduces the momentum of fluid entry into the retriever to prevent pistoning After pressurizing the force to move the outer barrel is that whi
30. iever inner barrel about four ounces 100 grams 9 Apply grease to the external surface of the retriever inner barrel 10 Stroke the retriever Extend and collapse the retriever until the oil and grease have been adequately filmed on all working surfaces 11 Test the retriever operation If the retriever still has a gritty feel and sound after the stroking procedure indicated above 1t must be disassembled for thorough cleaning and lubricating Retriever Disassembly 1 Collapse the retriever 2 Loosen and remove the mandrel rod stop nut 15 Remove the flat washer 14 3 Loosen and remove the four 3 8 Allen head cap screws 1 retaining the retriever head using a 5 16 Allen wrench 4 Remove the retriever head 10 and the mandrel rod stop washer 11 5 Withdraw the mandrel rod 12 from the inner barrel end 22 6 Loosen or remove the socket adapter assembly f required The socket adapter assembly may be left attached or removed from the mandrel rod To remove unscrew the two 5 16 Allen head cap screws with a 1 4 Allen wrench Slide the socket adapter off the mandrel rod and revolve its retaining key Remove the socket adapter pilot spring and flat washer by driving out the spring pin with a 1 4 punch 26 8 4 10 11 12 16 Remove the hammer nut retaining lock ring 13 Lift the last turn of the hammer nut retaining lock ring up and out of the groove work around the ring until the ent
31. ire ring comes out of its groove n the thread adapter 8 Loosen and remove the two 1 4 Allen head screws 26 which retain the thread adapter 8 by using a 1 8 Allen wrench Remove the thread adapter 8 from the inner barrel 22 by unscrewing one from the other Spanner holes are provided in the head end of the inner barrel 22 and in the sides of the thread adapter 8 to accommodate the spanner wrench Remove the hammer nut 7 and retaining lock ring 13 Slide seal installation tool P N 210473 over threads of inner barrel 22 If tool is not available wrap threads with teflon tape to protect the outer seal P N 201928 from damage Loosen and remove the four 3 8 Allen head cap screws 1 to remove the seal stop collar 9 Carefully remove the seal assembly by sliding them over the protected threads of the inner barrel Stand the retriever in a vertical position with the inner barrel 22 thread end downward Push down on the outer barrel 20 until the inner barrel head end is exposed Pull the inner barrel 22 out of the outer barrel 20 Remove the seals from the inner barrel 22 It will be necessary to first remove the four 1 4 socket head cap screws 15 in the head of the inner barrel 22 Remove the cap 24 and seal retainer assembly by carefully prying on side then the other with a small slotted screwdriver Remove the retriever bleed valve assembly 4 or 33 from the outer barrel 20 The bleed
32. is in the open position partially close and then fully open the service valve This will help to remove solids or particles from the seat area or carrier Close all valves Close the surge tube bleed valve the service valve and the service valve equalizing valve Open the surge tube bleed valve and allow the surge tube pressure to bleed off Close the surge tube bleed valve If the optional diverter hose assembly s being used during the operation 1t should be removed at this time Remove the surge tube assembly Using the brass hammer tap loose and fully unscrew the surge tube hammer nut WEAR SAFETY GLASSES Lift the surge tube assembly from the service valve Steel Pipe Plug Adapter 125115 The steel pipe plug adapter is used to install or allow retrieval of the 1 2 steel pipe plug while plug assemblies are under pressure This tool is used in cases where bleed off cannot be accomplished The procedure described for the steel pipe plug adapter differs from the other tools described in this section in that the service valve 18 assumed not to be installed and that the plug assembly is assumed to be present within the access fitting body 1 Attach the pipe plug adapter to the square head of the pipe plug and tighten the Allen head set screws Install the service valve onto the access fitting body in the same manner as described previously n Section 4 paragraphs 6 7 and 8 Open the service valve ball Install the
33. lling the protective cover thoroughly grease the acme threads on the access fitting body This measure will save many hours of cleaning when the access fitting is next serviced 16 SECTION 6 0 RETRIEVER BACK PRESSURING Back pressuring is the pressurizing of the retriever from an external source through the retriever bleed valve This procedure may be necessary when the plug assembly will not allow line pressure to bleed past 1t within the access fitting body or removing fittings at high pressures with the RBS retriever Several means of back pressuring may be used a Nitrogen bottle b Hydraulic Part No 203855 or pneumatic pump adjacent tee access fitting utilizing its line pressure The nitrogen bottle method is the procedure described The procedure assumes that the retriever and service valve are connected to the access fitting body 6 1 Connect a high pressure hose to the retriever bleed valve 6 2 Nitrogen bottle connection Connect the other end of the high pressure hose to the nitrogen bottle outlet It is recommended that a The nitrogen bottle pressure be at least 200 psi 13 BAR higher than the line pressure b The nitrogen bottle be equipped with a regulator The nitrogen bottle be fitted with a bleed valve This 15 desirable to allow bleeding down the hose after back pressuring is completed 6 3 Nitrogen bottle control valve Open the control valve and allow pressure build up withi
34. n the hose to 100 psi 6 BAR above the line pressure 6 4 Open the retriever bleed valve and allow the nitrogen pressure to enter the retriever Normally the pressure will come to a balance and the excess pressure will enter the operating line A back pressure or pressure flow reverse will have been accomplished In doing so debris contaminants or other obstructions within the retriever service valve plug assembly or access fitting body will be dislodged to enter the product stream flow 6 5 Close the retriever bleed valve 6 6 Close the nitrogen bottle control valve Bleed off the pressure within the hose and disconnect 1t from the retriever bleed valve emove plug assembly in the normal manner and as previously described in Section 6 7 R the pl bl tl al d ly d bed in Secti 17 18 SECTION 7 0 RETRIEVER amp SERVICE VALVE SPECIAL TOOLS When using the service tools described within this section it is advisable to use the shortest stroke and consequently the lightest retriever available Besides easier handling it will provide the best feel when using the special tools The following procedures assume that the service valve is installed on the access fitting body and that it is in the closed position The plug assembly is also assumed to be absent from the access fitung body 7 1 Thread Tap Assembly 125111 The thread tap assembly 1s used to clean debris from threads or to rep
35. n the mandrel rod stop nut 15 with a socket Torque the four 8 8 Allen head cap screws 1 that were initially installed as indicated in paragraph 8 to retain the retriever seal stop collar 9 to 45 ft Ibs Install the retriever bleed valve assembly 4 or 33 Position the key in the mandrel rod 12 and reassemble and install the socket adapter assembly if it was removed Position the two 5 16 cap screws in the third and fifth holes from the socket adapter pilot end for normal service 29 22 Stroke the retriever to ensure it slides easily and does not bind Ifthe retriever does bind loosen the eight 3 8 cap screws 1 four at the head 10 end and four at the seal stop collar 9 end Stroke the retriever Re tighten all eight cap screws 1 to 45 ft Ib the retriever should now stroke freely Pressure test the retriever Rated working pressure is 2500 psi 17 2 MPa for the model RBSA or 6000 ps 41 3 MPa for the model RBS retriever Note that the pressure rating for the retriever s engraved on the outer barrel of the tool 30 SECTION 9 0 3600 PSISERVICE VALVE MAINTENANCE The maintenance interval required for the service valve will be determined by the media acting upon the valve Sand grit or metal chips may damage seats causing leaks which will require seat replacement Occasional lubrication will be necessary to reduce opening torque The use of a synthetic lubricant such as Cosasco 201688 s recomme
36. n the retriever bleed valve and allow bleed off for approximately twenty seconds Normally this is sufficient time for debris to be flushed from the access fitting body threads 19 7 2 10 11 13 Close the retriever bleed valve Remove the diverter hose assembly Retriever the tap Turn the retriever outer barrel counterclockwise for about 14 to 17 turns until the tap threads are fully disengaged from the access fitting body threads Extend the retriever Close the service valve ball and the service valve bleed screw Bleed and remove the retriever Open the retriever bleed valve and allow pressure to bleed off completely Using the brass hammer tap loose and fully unscrew the retriever hammer nut WEAR SAFETY GLASSES Lift the retriever from the service valve Remove the tap Unscrew the tap from the socket adapter pilot NOTE If the tool flutes have a large amount of debris it is recommended that the surge tube assembly or thread brush assembly be used to clean the access fitting body and threads prior to reinstalling the plug assembly See part 7 3 and or 7 2 following Thread Brush Assembly 125116 The thread brush assembly 1s used to clean small amounts of debris from the access fitting body threads 6 Attach the thread brush assembly to the socket adapter pilot threads Connect the retriever Extend the retriever fully Lift the retriever and place it onto the service valve If the access fitting to
37. nc RCS warrants this RCS Corrosion Monitoring Product Product to be free from defects in material and workmanship for a period of eighteen months from the date of purchase from RCS or an authorized RCS distributor or one year from the date first placed in service whichever comes first with the following exceptions RCS Corrosion Monitoring Products are routinely exposed to process fluids under a variety of operating conditions Because RCS cannot anticipate all possible combinations of process fluid composition operating conditions and materials of construction RCS makes no warranty as to compatibility of its products in the application conditions CORROSOMETER probe sensing elements CORRATER electrodes and COSASCO coupons are designed to corrode As corrosion proceeds the structural integrity of the corroding surfaces is unavoidably affected RCS makes no warranty and specifically disctaims all warranties as to structural integrity of any of these products left exposed to the process beyond their intended service life RCS does not warrant Products not manufactured RCS This Limited Warranty does not include service to repair damage to the Product resulting from shipping improper installation or use accident disaster abuse attempts to service the Product by unauthorized personnel or non RCS modification of the Product Should RCS determine that the Product has failed within the warranty period RCS will as its
38. nch Remove the position stop plate 25 which is now exposed 4 Remove the four 7 16 Allen head cap screws 23 and the two 1 2 Allen head cap screws 24 retaining the bonnet 2 to the valve body 1 by using a 5 16 and 3 8 Allen wrench respectively Remove the bonnet 2 and stem intact from the valve body 1 Remove the bonnet to valve body o ring seal 11 which is now exposed 6 Remove the valve ball 12 from the valve body 1 Remove second seat seal ring 15 and its 13 from the valve body Remove the carrier seal 14 which is now accessible 81 Further disassemble the stem 3 from the bonnet 2 previously removed in paragraph 5 and remove the stem seal 9 its back up ring 8 and the thrust ring 10 which are now exposed Remove the by pass or vent valves 22 only if necessary for seal replacement To remove turn the large bleed screw retaining lock nuts counterclockwise and completely disengage from the service valve body 1 To disassemble the bleed screws from their retaining lock nuts it is necessary to remove the roll pins and the small nylock hex nuts from the bleed screw tops By turning clockwise on the bleed screws they will thread out through the bottom of their retaining lock nuts Service Valve Assembly 1 6 Clean all parts Examine all seals and o rings It is highly recommended that seals and o rings be replaced each time the service valve
39. nded 9 1 92 Sour Gas Service On both the 3600 PSI and 6000 PSI service valves applicable materials comply with the requirements of NACE standard MRO175 Sulfide Stress Cracking Resistant Metallic Materials for Oil Field Equipment As stated in this standard Materials are resistant to but not necessarily immune to sulfide stress cracking under all service conditions Thus when the valve is used in sour environments it must be thoroughly cleaned after use to help prevent corrosion and or damage to internal materials Service Valve Disassembly Applicable to 3600 pound service valve kit P N 061001 valve P N 601000 The RBSA RBS service valve has a valve ball that is removable only from the service valve hammer nut end access fitting body connection 1 Remove the four 3 4 Allen head cap screws 19 at the hammer nut end 20 using a 5 8 Allen wrench The cap screws 19 secure the hammer nut assembly 20 to the valve body 1 9 Remove the hammer nut assembly 20 and retainer 16 from the valve body 1 exposing the first of two seat seal rings 15 and their carriers 13 Remove both the seat seal ring 15 and its carrier 13 from the valve body 1 Remove the retainer to access fitting body o ring 18 and retainer to valve body o ring 17 which are now accessible 3 Remove the 5 16 Allen head cap screw 4 securing the valve handle 5 to the square head of the stem by using a 1 4 Allen wre
40. option repair or replace the Product at no charge except as set forth below Repair parts will be either reconditioned or new All replaced parts and Products become the property of RCS To obtain Limited Warranty service you must contact RCS s Customer Service Department to obtain a Return Authorization Number and Shipping Instructions NO PRODUCTS WILL BE ACCEPTED FOR RETURN WITHOUT A RETURN AUTHORIZATION NUMBER You agree to be solely responsible for all costs of removing the Product from service shipment including insurance to and from the designated RCS Service Center and reinstallation RCS will be responsible for the cost of return shipment for any valid warranty claim RCS reserves the right to inspect an allegedly defective Product at the place of installation or use If RCS determines that there is a valid claim there wili be no charge for such inspection In all other cases any inspection by RCS will be at the rates specified in RCS s then current published Field Service Rate Schedule THE FOREGOING WARRANTIES ARE IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE This Limited Warranty is extended to the original user for industrial use on y and is not a consumer product warranty extended under the Magnuson Mass Warranty Act IF THIS PRODUCT IS NOT IN GOOD WORKING ORDER AS WARRANTED ABOVE YOUR SOLE REMEDY SHALL BE REPAIR OR R
41. point the retriever should have bled off pressure completely This may take up to two minutes to complete Close the bleed valve When the retriever is completely depressurized disconnect the diverter hose assembly and close the bleed valve WEAR SAFETY GLASSES Tap loose the retriever hammer nut using the brass hammer According to weights indication in paragraph 10 for the various size stroke retrievers it may be advisable for two men to help each other in removing the retriever from the fitting Lift the retriever to remove from the service valve Do this carefully If the product media is liquid a certain amount will ooze at the disconnect Junction or from the retriever Remove the wood clamp If it was installed on the inner barrel as indicated in paragraph 18 and collapse the retriever Check retriever operation Stroke the retriever extend and collapse if it seems difficult to operate feels or sounds gritty cleaning and lubricating before further use is recommended SECTION 3 0 INSTALLATION OF SOLID OR HOLLOW PLUG ASSEMBLIES UNDER PRESSURE The following procedure assumes the service valve is installed on the access fitting body and is in the closed position The retriever must be in a cleaned and lubricated condition 5 1 Prepare the plug assembly a Visually inspect the plug assembly threads and clean or repair 1 necessary Minor repairs can be done by usin
42. r still has not balanced wait for 10 to 15 minutes DO NOT BACK OFF THE PLUG ASSEMBLY MORE THAN A TOTAL OF 4 TURNS d The retriever bleed valve can be opened to test for the presence of pressure n the retriever If after waiting the required 10 to 15 minutes the pressure has not entered the retriever the plug assembly or the retriever has encountered an obstruction or accumulation of dirt or debris Back pressuring the retriever should be the next step for relieving the obstruction See Section 6 Retriever Back Pressuring 10 16 17 18 19 20 Retrieving the plug assembly from the access fitting body a When the retriever has pressure balanced with the line the plug assembly can be disengaged from the access fitting body b Turn the retriever outer barrel counterclockwise approximately 15 or 16 turns to completely disengage the plug assembly from the access fitting body Ensure that the socket adapter hex and the plug assembly hex remain engaged during this operation Disengagement will allow the socket adapter pilot to unscrew from the plug assembly leaving the plug assembly in the access fitting body Refer to paragraphs 12 and 14 After the plug assembly s removed from the access fitting body extend the retriever outer barrel with a twisting turning sliding motion Extend the retriever outer barrel until the plug assembly and its attached corrosion monitoring or preventing device is withdrawn f
43. ratures 40 to 600 40 to 316 C Available as COSASCO 201688 8 1 Sour Gas Service On both the RBS and RBSA retrievers applicable materials comply with the requirements of NACE standard MRO175 Sulfide Stress Cracking Resistant Metallic Materials for Oil Field Equipment As stated in this standard Materials are resistant to but not necessarily immune to sulfide stress cracking under all service conditions Thus when the retriever is used in sour environments it must be thoroughly cleaned after use to help prevent corrosion and or damage to internal materials 8 2 Cleaning and lubricating without disassembly 1 Extend the retriever until the socket adapter s w thdrawn into the inner barrel by approximately 1 2 inch Place the retriever head end down on a clean surface 8 3 2 Add solvent Pour approximately pint 1 2 liter of solvent into the retriever inner barrel 3 Collapse the retriever slowly 4 Extend the retriever slowly The solvent while in the process of cleaning and flushing will remove all lubricant or at least emulsify sufficiently to make extension of the retriever difficult 5 Turn the retriever end for end With the retriever head end up let the solvent drain out 6 Repeat steps 1 through 5 7 Extend the retriever again as indicated in paragraph 1 The retriever head end should again be placed down on a clean surface 8 Pour SAE 30 weight motor oil into the retr
44. rel 22 Remove the Teflon tape that was applied Grease the thread end of the inner barrel 29 Tighten the thread adapter 8 onto the inner barrel 22 using the spanner wrench Install and tighten the two 1 4 Allen head set screws 26 with a 1 8 Allen wrench and torque to 70 in lbs Install the retaining lock ring 18 onto the thread adapter 8 by feeding the leading edge into the groove and then working around the ring Clean the mandrel rod 12 with solvent Examine the mandrel rod 12 for damage Apply grease liberally to the entire length of the mandrel rod 12 including the chamfer at the threaded end Pull the thread adapter 8 until the inner barrel 22 is withdrawn from the outer barrel 20 and has approximately two inches exposed Insert the mandrel rod 12 threaded end first into the inner barrel 22 Gently push the mandrel rod 12 through the seal Lay the retriever on its side Continue pushing the mandrel rod 12 until the threaded end is exposed from the outer barrel 20 end approximately one inch Place the mandrel stop washer 11 onto the exposed threaded end of the mandrel rod 12 Place the retriever head 10 onto the mandrel rod 12 install the washer 4 and start the stop nut 15 Install the four 3 8 Allen head cap screws 1 through the retriever head screw 10 holes and into the outer barrel 20 screw holes Torque the cap screws 1 with a 5 16 Allen wrench to 44 ft Ib Tighte
45. retriever and engage the socket adapter in the same manner as described previously in Section 4 paragraphs 8 through 14 22 6 10 Pressure balance the retriever in the same manner as described previously in Section 4 paragraph 15 After pressure balance 1s achieved slowly turn the retriever outer barrel in a counterclockwise direction thus loosening the pipe plug Retrieval of the pipe plug Continue to turn the retriever outer barrel in a counterclockwise direction until the pipe plug 1s disengaged from the pipe plug assembly then extend the retriever fully If the access fitting to be serviced is mounted on the top of line install the wood clamp on the inner barrel to prevent the retriever outer barrel from collaps ng of its own weight Close the service valve Open the bleed valve and bleed off pressure Using the brass hammer tap loose the retriever hammer nut and unscrew fully WEAR SAFETY GLASSES Lift the retriever from the service valve Remove the wood clamp if it was installed Collapse the retriever to expose the socket adapter the attached pipe plug adapter and the pipe plug Remove the adapter and the pipe plug from the socket adapter pilot Reinstall the retriever on the service valve and remove the solid plug assembly in the same manner as described previously in Section 4 paragraph 9 and on the conclusion of the Section 23 24 SECTION 8 0 RETRIEVER MAINTENANCE The maintenance interval required
46. then clockwise again to engage the threads Do not use excessive force and be sure that the threads engage properly to prevent cross threading b If cross threading does occur the plug assembly will have to be removed observing all of the procedures as outlined in Section 4 Retrieval of Solid or Hollow Plug Assemblies under Pressure Also see Section 7 Retriever and Service Valve Special Tools Tap Assembly 125116 To complete the engagement of the plug assembly to the access fitting body turn the retriever outer barrel 14 or 15 turns The plug assembly should be barely or lightly seated Tighten only 1 4 turn after the primary packing contacts its seat within the access fitting body This will leave sufficient room for travel for orientation using the index mark mentioned previously If the plug assembly does not seat properly 1t may be caused by one of the following a Damaged plug assembly thread Remove and repair with thread die assembly 125112 or replace the plug assembly b Damaged access fitting body thread The use of thread tap assembly part number 125111 is recommended Sand or chips in the threads Use thread brush assembly 125116 surge tube assembly 123672 or the magnetic swab assembly 121870 d Monitormg or preventing device hitting the bottom of the pipe This will require replacement with a shorter device e Monitoring or preventing device hitting an obstruction at the access fitting body
47. ully past the service valve ball Install the wood clamp onto the inner barrel if the fitting is mounted in a position to allow the retriever outer barrel to collapse of 1ts own weight Close the service valve equalizing valve and the service valve ball a Close the service valve equalizing valve The service valve extension handle features a slotted end to engage the roll pin of the equalizing valve stem for easy opening and closing b Close the service valve ball using the service valve extension handle Bleed off retriever pressure The retriever 1s still fully pressurized at this stage and this pressure must be fully relieved An optional diverter hose assembly s recommended when bleeding off retriever pressure fluids can be collected n a container or diverted to a safe area away from the operator The hose is attached by quick connect to either the retriever bleed valve or the open port in the service valve Optional diverter hose assemblies are 124669 diverter hose assy 10 ft 3 0 m 124931 diverter hose assy 25 ft 7 6 m 124685 diverter hose assy 50 ft 15 2 m 11 22 23 Bleed the pressure from the retriever by opening the retriever bleed valve one or two turns for gas or liquid on bottom or side position For top locations remove the service valve port plug and then open the service valve bleed valve one or two turns Watch the pressure gauge a gradual drop to zero should be indicated at which
48. ur feet should be provided with the fitting placed off center one foot from the culvert wall 2 Adjust the socket adapter assembly For solid or hollow plug assemblies the socket adapter should be set in the second and fourth holes from the hex end When retrieving the hot tap plug assembly with the 14 or 18 stroke retriever the socket adapter must be in the first and third holes from the hex end 3 Remove the access fitting cover 1f present After removing the cover check the access fitting body to ensure that the o ring contact area is clean and that the acme thread 1s in good condition 6 If the thread has been painted or damaged 1t should be repaired by brushing or filing The use of the optional heavy protective cover manufactured of steel is recommended since it is more durable Loosen the plug assembly It is recommended that prior to removing either the plastic or steel pipe plug the plug assembly be unfrozen from its seat Using either a 1 1 8 socket or a 1 1 8 box end wrench loosen the plug assembly by turning counterclockwise to a maximum of 1 4 turn DO NOT loosen beyond the 1 4 turn maximum or leakage will result Tighten the plug assembly Remove the pipe plug from the plug assembly The solid plug assembly uses a stainless steel pipe plug with a 1 2 square head which acts as a secondary seal Hold the plug assembly hex with a box end wrench to prevent 1t from backing off while usin
49. valve for safe bleed off The retriever s internal wetted parts are hard chrome plated to provide a long life and reliable sealing 6 SECTION 2 0 SAFETY CHECKLIST Safe operation requires a minimum of 2 tramed operators Do not use this retrieval equipment unless you have been trained in its safe operation If it has been longer than 90 days since your last operation you should review the manual and first practice on a dummy fitting prior to use Make sure you have complied with all plant safety requirements and environmental regulations Identify the type media its pressure and temperature Review material safety data mformation on the media prior to operation Insure you have all the required safety equipment for the given media 1 e hard hat safety glasses protective clothing safety gloves respirator spill safety equipment etc Any actions which could vary system pressure such as surges caused by opening and closing of valves and chokes should be delayed until completion of retrieval operations Insure you have enough clearance for safe operation Note wind direction prior to starting operations involving hazardous products SECTION 3 0 RETRIEVER amp SERVICE VALVE CONSTRUCTION amp OPERATION RBSA retrievers feature a stainless steel outer barrel Viton o rmgs Teflon back up rings and graphite impregnated Teflon dynamic seals They are pressure rated to 2500 psi 172 BAR and have a maximum operating temper

Serial Number - Rohrback Cosasco Systems

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