User Manual QTS Lift/Test Cap
Contents
1. 5 4 1 Dis Assembly Remove circlip and remove collar Remove Spring Seals and discard Remove Saver Sub and remove O ring and backup and discard Re Assembly Fit O ring and backup to Saver Sub and refit to cap Fit Spring Seals to test cap Place collar over test cap and hold in place using circlip OPS 4852 RevA 5 User Manual N Phuel Lift Test Cap 5 5 Maintenance Record Sheet Date Type of Performed Verified Comments Performed Maintenance By By G Table 2 Maintenance Record OPS 4852 Rev A 6 Ti User Manual N Phuel Lift Test Cap 6 Testing All testing is to be carried out in the designated test area and by suitably qualified and competent personnel WARNING Trapped air requires considerable time to compress and when it is compressed is highly dangerous It has enough stored energy to separate parts with considerable force Fit appropriate test caps and blanking plugs Fill with testing fluid bleeding off any air within the system Apply a pressure of 500 psi and ensure pressure holds for a minimum of 10 minutes Increase pressure to Maximum Working Pressure allow to stabilise and maintain this pressure until it is evident there are no apparent leaks Testing to be carried out to Test pressure when decreed by maintenance schedule Bleed off pressure drain test fluid and dry Remove test caps Apply coating of de wate2. to Section 4 1 and Section 4 3 for details 5 2 2 5 2 4 6 Monthly Carry out a thorough inspection of the Lift Test Cap and Shackle reporting any signs of defect Yearly Disassemble Lift Test Cap clean and degrease all components Inspect the condition of all sealing surfaces and surface coatings Re coat threads and sealing surfaces if necessary If in doubt contact Phuel Oil Tools Ltd Replace all elastomeric seals with items from redress kit see spares Error Reference source not found Regrease components Re assemble Pressure test to maximum working pressure in accordance to testing procedure Inspect paint work and repair as necessary Five Yearly Yearly Maintenance plus the following Remove the blanking plug Carry out 100 surface NDE on all surfaces Pressure test to test pressure witnessed by certifying authority OPS 4852 Rev A 4 User Manual N Phuel Lift Test Cap 5 3 Safety Many of the components are heavy and should not be lifted without lifting aids Ensure all pressure testing is carried out in the appropriate testing area by suitably qualified personnel Wear appropriate personal protective equipment Do not over exert yourself while using torque wrenches Use appropriate mechanical advantages when available Ensure that all tools and equipment are in good condition and are suitable for the intended use Clear up any fluid spills immediately to avoid slips 5 4 Redress Procedure
3. 4965 HVO ee ee ee ee ee Figure 1 Lift Test Cap issie n ie BE RE SG Ee bei oe Eie ee ei Ee EE Ee Figure 2 175 4965 HVO siese Ens es ee Ri ee Ee ee EE eg oe Re ee be OPS 4852 Rev A Bi N Phuel User Manual Lift Test Cap Revision History Issue Release Date Description Rev A 26 Jul 12 Initial Issue OPS 4852 Rev A _ User Manual N Phuel Lift Test Cap Safety WARNING Trapped air requires considerable time to compress and when it is compressed is highly dangerous It has enough stored energy to separate parts with considerable force All pressure equipment has a particular pressure rating and care must be taken to ensure that no item is used in a situation that may cause its working pressure to be exceeded All personnel involved in pressure testing must be formally trained and wearing the appropriate PPE The lifting eye has a safe working load of 12 tonnes and is marked accordingly This equipment and the equipment it is attached to is heavy never position yourself below a suspended load OPS 4852 Rev A ili User Manual N Phuel Lift Test Cap 1 Introduction 1 1 General The Lift Test cap is designed to allow the pressure testing and lifting of equipment This user manual serves as an introduction to the equipment and contains the relevant specifications operation planning and maintenance instructions parts list and drawings 1 2 Produc
4. N Phuel Unit 17 Denmore Industrial Estate Denmore Road Bridge of Don Aberdeen AB23 8JW User Manual QTS Lift Test Cap This Manual Covers the Following Part Numbers 175 4965 HVO OPS 4852 Rev A User Manual N Phuel Lift Test Cap Table of Contents Ei Oneal Renee Ree ee mee ee ee ne ee Ne nee ee nee ee ne 1 2 Product Identification iste 2 Technical Specification eis EE EE ER EE AG sees ES EE SEA SEGE EE Ke ER ceeeeaeeens utes 3 Technical Description ii EE SERE EE RR BA EE Be EER be ee RE ee ASe EE eN se Se Ms ie AA OE EA OE rere errnrr revere ED EED EE OR OD IE OR ED EER ED HE ER EO HE 2 EE OO EE EE en aati N RA ME EE EE EE EE EE EE ME EE ME EE EE rr rrr 5 1 TMOG OP siese Ge ee ee ee Re ee Re 52 I NS CM RS ER RE ER GR Ge ee Rd 5 2 1 Pre amp Post JOD N OE i 52 2 6 Monthly EER EE RE u ER KAN IE EE EE eevee EE EA 524 FING Year si EE ER GE ED EE Re RD BEE ae SE 5 OUI E E N ee GE 5 4 Redress Procedure issie ee ee ee ee 5 4 1 Ba TE le EE buna 54 2 ReAssembly RR EE GE SG ER ee ES 5 5 Maintenance Record Sheet i iii see ee 6 EE EE RO EE OO OE OE OR 7 Parts List and Drawings eek Ee ei Ee eo AE RR ee EG Se EE EE E RE OE ER EE ER OE EO 8 1 Individual GINS ii se GE EE RE Ee GR ee ED 8 2 Supporting Equipment ss sesse ee ee ede ee ee ee ee ee ee ee ee ee ee Table 1 Technical Data ee ee ee ee ee ee ee ee ee Table 2 Maintenance Record ee ee ee ee Table 3 Parts List 175
5. ersonnel e Attach Lift Test cap to the lower half of the QTS e Fill equipment under test with appropriate test fluid bleeding off any air e Test equipment using procedure laid down in appropriate user manual 4 1 Pre Job e Check maintenance record sheet to ensure the equipment has been maintained by competent personnel e Check all certification is in date e Ensure equipment to be tested does not exceed the maximum working pressure or the safe working load e Ensure Spring Seals are seated correctly and there are no signs of damage e Ensure threads are clean e Inspect for signs of damage defect 4 2 During Job e Ensure no leaks form equipment 4 3 Post Job e Inspect for signs of damage e Inspect Spring Seals for seating and signs of damage replace if required with appropriate item from redress kit e Ensure threads are clean OPS 4852 RevA 3 User Manual N Phuel Lift Test Cap 5 Maintenance All maintenance to be carried out by suitably qualified and competent personnel 5 1 Introduction Regular maintenance of the equipment using Phuel redress kits or Phuel approved parts is essential to its continued safe operation Ensure that the pre and post job operating procedures are followed and that maintenance records are kept 5 2 Schedule The maintenance schedule may be governed by international or company standards and the following is considered to be the minimum requirements 5 2 1 Pre amp Post Job Refer
6. le risk of the user 8 2 Supporting Equipment The lift cap is compatible with the following QTS assemblies Part No Description 117 3631 HVO QTS INSITUE OU 9 4 BOX X 9 4 PIN COLLAR 117 3962 HVO QTS INSITUE QU 8 25 4 BOX X 8 25 4 PIN COLLAR Other Phuel OTS assemblies may be compatible if the middle connection is 9 4 ACME OPS 4852 Rev A 9
7. ring solution to protect the bore and threads Fit thread protectors On completion of all maintenance ensure the maintenance record sheet Para 5 5 is completed OPS 4852 Rev A 7 n User Manual N Phuel Lift Test Cap 7 Parts List and Drawings Item Part Number Description 1 175 4964 480 LIFT TEST CAP BODY QTS 9 00 amp 8 25 RMEC 125 2059 480 COLLAR SOLID 9 4 145 2176 480 SAVER SUB PORT 801 0119 V90 O RING B S SIZE 119 SHC 0583 3A4 SOC HD CAP 1 2 UNC LENGTH 3 4 IN WNL 0580 316 WASHER NORDLOCK M12 180 2159 STL EXTERNAL CIRCLIP 200mm oa ro ro 4 2 NI OOP EO Po Table 3 Parts List 175 4965 HVO Note Thread Protector item 100 not shown in assembly drawing 9 00 4 ACME BLUNT START 10 0 Figure 2 175 4965 HVO OPS 4852 RevA 8 User Manual N Phuel Lift Test Cap 8 Spares Use only spares supplied or approved by Phuel Oil Tools Ltd It is recommended that sufficient quantities of the following spares be maintained to ensure that the equipment is always available when required Elastomeric spares are supplied in Viton material as standard Many other materials are available please specify when ordering 8 1 Individual ltems Individual items may be ordered as reguired using the part number specified Note O Rings conform to industry standards and may be substituted with those from other suppliers at the so
8. t Identification Phuel products are identified by a unique serial number that facilitates full product traceability Each product is supplied with a documentation pack that contains product certification and material inspection reports The serial number is always etched on the surface of the product but can sometimes be difficult to find or read after painting A customer identification number is also included to allow the customer to track the asset in their system The nameplate tag is secured to the top of the Cap and is stamped with the information shown below This tag should be located in the first instance to ensure that this manual refers to the correct equipment Phuel Oil Tools Ltd Description amp Size Part Number Phuel ID Customer ID API Details MWP amp Service OPS 4852 Rev A 1 User Manual N Phuel Lift Test Cap 2 Technical Specification Part Number 175 4965 HVO Connection NE Vo NPT Maximum Working Pressure MWP 10 000 Psi Working Load Limit WLL 12 Ton Weight 122lbs 55 kg Table 1 Technical Data TTACH ID TAG HERE Figure 1 Lift Test Cap OPS 4852 Rev A 2 User Manual N Phuel Lift Test Cap 3 Technical Description The Lift Test cap is used in conjunction with a Phuel Quick Test Sub QTS to allow pressure testing and lifting while the QTS is separated 4 Operation All operations to be carried out by suitably qualified and competent p
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