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User`s Manual in PDF - Alabama Specialty Products, Inc.

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1. see pressure gauge on the pump 5 Close retriever head valve and disconnect the hoses from retriever 6 Make sure that the o ring at bottom of service valve is in good conditions 7 Screw the service valve on the access fitting and ensure that the service valve is in proper position and the by pass is closed 8 Place the retriever on the service valve 9 Screw the rod into the plug by rotating the retriever 10 Connect hoses and open the head valve 11 Set pump to retrieve and pump slowly in order to be able to screw and tighten the hummer nut Onto the service valve 12 Check that the bleed valve of retriever is closed 13 Set the pump to install and pump to approx 725 psi 50 bar over the line pressure ask control room about the line pressure 14 Release the locking pin according to the sequence showed in this manual until they are flush with access fitting 15 Set pump to retriever and pump until pressure is built up inside the retriever max 1450 psi 100 bars If line pressure at least 87 psi 6 bar is sufficient to retrieve without pumping set the pump to neutral open the retriever head valve slowly and wait until the pressure in the pump is O At this point the pressure gauge of the retriever must indicate the same line pressure 16 Close the service valve 17 Release the pressure with the retriever valve bleed valve 18 Unscrew the retriever from service valve loosing the hummer nut 19 Place the
2. Bleed off the pressure inside the service valve by opening the retriever s or service valve s bleed off valve carefully Use a hose and a can to do this in a controlled manner The same safety precautions as for retrieval operations shall apply see section 4 4 step 22 for further advice Tighten all locking pins on the access fitting The pins must be tightened evenly around the access fitting in order to avoid the plug being pushed against one side of the fitting Therefore screw in all pins until they touch the plug Then tighten one by one fig 13 approx 1 4 of a turn and repeat until all locking pins are sufficiently tightened Expect a total of 3 4 turns for adequate tightening If the locking pins suddenly stop after only 1 3 turns or if they can easily be screwed all the way in 4 5 turns without any resistance this indicates that the plug is not quite in position Loosen all pins retrieve the plug probe assembly again and look for damages that might prevent proper installation see section 4 4 step 17 25 Cycle for tightening of locking pins Fig 13 When the plug is fixed in position by the locking pins the pressure in the retriever can released Set the pump to RETRIEVE and pump 1 2 strokes The gauge on the pump shall now show 0 Close the bleed off valve and wait for 1 2 minutes Then open it again and see if pressure has built up inside the retriever A pressure build up indicates that the plug is no
3. as follows 2 BALL VALVE NEEDLE VALVE SERIE 6000 SEAL CARRIER BY PASS STEM PIN 5X50 to note that the quantity are two for each item Item 3 Balls might need replacement if the Double Service Valve is used on systems with large amounts of sand or other particles that might cause scratches or other damages to the surface of the Balls Such damages might cause minor leaks when the Valve is used on gas systems Please note that the Balls are also included in the Repair Kit C F Call Factory 35 6 3 Pumps 6 3 1 Manual Hydraulic Pump Under normal operating conditions the following spare parts are sufficient to keep the Manual Hydraulic Pump in good operating condition Item Spare part Part No Material 1 Repair Kit for Manual Hydraulic Pump SEE PUMP MANUFACTURER 2 Hydraulic Hose with Quick coupling installation side 3 Hydraulic Hose with Quick coupling retrieve side Item 1 Repair Kit includes all seals and other components that usually will require replacement when the pump is to be overhauled Ask directly to pump manufacturer Item 2 and 3 Hydraulic Hoses with Quick Couplings shall always be replaced if there are visible damages in the outer sheet of the hose The Quick Couplings are different on the two hoses to avoid the hoses from being incorrectly connected so please make sure to order the correct hose 6 32 Air Hydraulic Pump Under normal operating conditions the
4. connect it to the Back Pressure Quick Coupling Assy on the Bleed off Valve Ensure that the bleed valve is open fig 12 e Keep the pump in RETRIEVE position and pump until the pressure inside the retriever equals or exceeds the line pressure Then close the Bleed off Valve e Move the hose from the Bleed off Valve back to its original position e Check and make sure to have enough hydraulic oil inside the pump Dleed valve Male quick connect quick connect gm with female Fig 12 6 With the line pressure in the retriever check for leaks between the retriever and the service valve If no leaks occur open the service valve For double isolation valves open the lower ball 7 Setthe pump to INSTALL and pump until the plug probe is installed into its position 18 inside the access fitting The number of pump strokes required for this operation depends upon the line pressure and the size of the retriever If using an air pump the time required for this operation will be approximately 50 seconds When the plug probe is in position inside the hydraulic access fitting the gauge on the pump will show that the pressure inside the retriever increases for each new pump stroke without dropping afterwards The retriever pressure should now be increased to 725 1450 psi 50 100 bar above line pressure in order to ensure that the primary packing on the plug gets properly positioned into its seat
5. ine tne n p te etre Ere ted dod 37 7 1 Double Acting Hydraulic Retriever sese 37 7 1 1 General Arrangement Drawing with Part List 37 7 1 2 Detail for Seals on rear section of Retriever 38 7 1 3 Detail for Seals on center section of 38 7 1 4 Detail for Seals on front section of Retriever 39 7 1 5 Detail for Seals on Retriever Head 39 7 2 Single Isolation Service Valve sssssssssssssssssssseseeeneeee eene enne nnne 40 7 2 1 General Arrangement Drawing with Part List 40 7 3 Double Isolation Service Valve ssssssssssssssssssseseeeeeeeneeeee nennen ener 41 7 3 1 General Arrangement Drawing with Part List 41 CHAPTER 8 Sequence of Operations nennen 42 CHAPTER 1 Introduction 1 1 Conformity to the Pressure Equipment Directive PED The Tool subject of this manual Hydraulic Retrieval Tool and Service Valve Double and Single Ball are in compliance with Pressure Equipment Directive PED Where potential hazards have been identified appropriate warnings and safety precautions have been described throughout the manual CHAPTER 2 Main Data 2 1 Guarantee Restriction Visually inspect all components for shipping damage If shipping damage is found notify carrier at once Shipping damage is not covered by the warranty The carrier is
6. responsible for all repair and replacement costs resulting from shipment damage WARNING Read and follow all instructions warnings and cautions to avoid personal injury or property damage during system operation METAL SAMPLES is not responsible for damage or injury resulting from unsafe use of product lack of maintenance incorrect installation of equipment and or system operation Contact METAL SAMPLES in case of doubt about any applications and safety precautions described herein 2 2 Tool Data Hydraulic Retriever The Double Acting Hydraulic can be used for replacing e g corrosion probes under full line pressure without shutting down and depressurizing the pipe system The Double Acting Hydraulic Retriever is supplied with a Service Valve with single isolation one ball as standard For more safety a Service Valve with double isolation two separate balls is also available NOTE Due to the increased height of the Double Isolation Service Valve a special Double Acting Hydraulic Retriever is required for use with this valve The Hydraulic Retriever can be operated either with a manual hydraulic pump or an air driven hydraulic pump When using an air driven pump make sure that the pump is connected to an air supply with operational pressure between 39 118 psi 2 7 8 2 bar and a minimum air flow of 89 8 gallons min 340 l min Operative Data Max working pressure 6090 psi 420 bar Max Min worki
7. HA104072 61 9 in 1572 mm 31 5 in 800 mm HA104082 67 8 in 1722 mm 35 4 in 900 mm HA104092 73 8 in 1872 mm 39 4 in 1000 mm HA104102 79 6 in 2022 mm 43 3 in 1100 mm NOTE 1 If the Double Acting Hydraulic Retriever is used with standard mechanical fittings with a Hydraulic Adapter produced by Metal Samples the max probe holder length is reduced by 3 15 80mm 2 The Retriever Kit is delivered with a Manual Pump An Air Pump is available on request 3 The Single Isolation Service Valves must be only used with a Double Acting Hydraulic Retrieval Tools prepared for this type of Valve P N HA104011 up to HA104101 4 The Double Isolation Service Valves must be only used with a Double Acting Hydraulic Retrieval Tools prepared for this type of Valve P N HA104012 up to HA104102 2 3 Restriction on use The maximum limits for pressure and temperature specified in section 2 2 must be observed The owner of the pipe system where the retriever is to be used should also in cooperation with trained retriever operators evaluate the safety issues on the specific locations where the retrieval tool is to be used The total process from start to finish must be evaluated but especially the potential hazards caused by the gas liquid flowing inside the pipelines must be considered with special attention on the following e the media in the pipe cause damage to the seals standard O ring material is Viton in the Retrieve
8. and around the locking pins If leaks are discovered then put the cover back on and do step 3 6 once more fig 4 If the leaks cannot be stopped then put the cover back on and tighten it Leave the access fitting until a more thorough inspection can be performed during the next shut down of the system 7 Check external threads on access fitting Clean and lubricate if necessary Check for leaks Fig 4 8 Check and inspect the O ring on the bottom of Service Valve fig 5 9 Mount the service valve on the access fitting Tighten it to the fitting with the plastic hammer Check o ring _ Fig 5 10 Connect the hoses from the pump to the retriever Before using the pump observe the settings of the flow direction valve RETRIEVE and INSTALL fig 6 11 Ensure that the valve in the retriever head head valve is open 1 2 turns is sufficient For manual pumps also check that the return valve on the pump is closed Set the hand airpump to INSTALL and pump until the connecting rod is fully extended Continue to pump until the pressure inside the retriever is a minimum of 290 psi 20 bar watch the pressure gauge on the pump Then close the head valve and disconnect the hoses fig 6 12 13 14 15 Plow direction valve install connecting rod y Head valve Return valve Fig 6 Hold the retriever so the connecting rod faces the service valve Put the c
9. nennen nennen nnns 10 4 5 Installation of a Monitoring Device into a Pressurized Pipe 17 4 6 Training program for Operators nennen 20 CHAPTER 5 21 SEEE 21 21 5 2 Maintenarce lnstE cllOriS dicet e RE ELE EY GERI TY GERIT EE GERE UIROS 21 5 2 1 Routine Inspections before use sssssssssssssssseeseeeenenee eene nnns 21 2 23 5 2 3 Maintenance after 23 5 2 4 Storing preservation and maintenance of preservation 31 CHAPTER 6 Spare Parts List eene nennen nnne 32 6 1 Double Acting Hydraulic Retriever nennen 33 6 2 Service Vale erie iicet ine tien iie Hei die AAA ei de dei de d Fe HS 34 6 2 A Single InsulationMalv8 eue tiae eon eda Len eda tea ade Revels 34 6 3 PUMPS T 36 6 3 1 Manual Hydraulic 36 6 53 2 RUMPA ae 36 CHAPTER 7
10. retriever with opening up and set the pump to install 20 Pump until the probe plug are out 21 Unscrew probe plug from rod 22 Change corrosion probe coupon and carry out maintenance change primary packing and if needed wear rings e 42 INSTALLATION OPERATION ELE he Connect retriever to the pump Set the pump to install and pump until the rod is extended Mount the plug probe to the rod Set pump to retrieve and pump until the probe is retracted into the retriever Screw the retriever to the service valve and tighten the hummer nut Open valve by pass to balance the pressure Open the service valve and then close the by pass Set pump to install and start pumping until the plug seals to the access fitting As soon as this happens the pressure gauge of the pump will immediately jump to higher pressure than the line pressure continue pumping to approx 725 psi 50 bar over the line pressure Open the bleed valve of retriever and or service valve to release the pressure inside the cylinder Make sure that the gauge of the retriever shows O Tighten the 4 locking pins Loosen the hummer nut and unscrew it from service valve Set pump to install and pump until the connecting rod is fully extended Close the retriever head valve and disconnect hoses from retriever Unscrew the rod from the plug by rotating the retriever Remove the service valve from the fitting Screw the protective cover
11. the valve housing 11 Loosen the set screw M5x12 15 and remove the handle 14 from the valve stem 13 Unscrew the gland 12 from the valve housing Unscrew the valve stem 13 from the valve housing Remove seals 17 20 and compression ring from the valve housing If damage to any of the remaining parts quick couplings and handle has occurred these parts must also be removed checked and replaced as necessary 8 Remove all O rings back up rings and wear rings but leave the wiper ring 33 on the inner barrel in place These rings are very easily damaged when they are removed and should therefore only be removed when they are worn out and need to be replaced 9 Clean all parts thoroughly with a suitable detergent especially the internals of the main cylinder the O rings and wear rings and their grooves on the inner barrel and connecting rod 10 Check the seals and wear rings carefully If any of the seals have scratches or show other signs of wear they must be replaced If any of the wiper rings on the inner barrel need to be replaced see instructions for Replacement of wiper rings in the following section 11 Check all parts for damage especially the internal surfaces of the main cylinder and the inner barrel If all parts including seals are found to be in good condition the retriever can be assembled again The assembly shall take place in the reverse order of the described disassembly procedure Be absolut
12. 2 Loosen the six bolts on the main cylinder head 10 and remove the main cylinder head 2 and the protection ring 8 3 Hold the retriever over the can and pump slowly in RETRIEVE mode until the seals on the rear end of the inner barrel come out of the main cylinder 1 Put the wooden stick into the opposite end of the main cylinder and push the inner barrel slowly and carefully out of the main cylinder Be aware that as soon as the inner barrel comes loose from the main cylinder all the oil that is inside the retriever will flow out so make sure to keep the opening of the main cylinder over the can Also note that the 23 inner barrel is filled with hydraulic oil which will flow out of the four holes in the barrel 4 Unscrew the washer 5 from the end of the connecting rod and push the rod out of the inner barrel The retriever is now sufficiently disassembled for cleaning and inspection The following steps 6 and 7 should only be performed if the union thread adapter 6 pressure gauge 39 bleed valve 38 or cylinder head valve 11 20 are defect or leaks have occurred in connection with these parts 5 Loosen the set screw M5x5 24 on the union thread adapter 6 Unscrew the union thread adapter from the main cylinder use a special hook wrench and remove the hammer nut 10 6 Unscrew the pressure gauge 39 the bleed valve 38 from the cylinder 7 Unscrew the cylinder head valve assembly 11 20 by unscrewing
13. 3 and the valve inspected in order to determine the reason for this problem 21 Assume that the service valve is closed check that the by pass valve on the service valve is closed On double isolation service valves check both by pass valves If the by pass valve s cannot be closed the plug probe must be reinstalled and service valve s by pass system checked See installation procedure section 4 5 step 7 13 22 IMPORTANT This section contains information about how to bleed off the pressure inside the retriever after the plug has been retrieved and the service valve closed Please read this section carefully Before the retrieval operations starts it should be agreed upon with the operators or the control room what safety precautions should apply for bleeding off the media in the retriever see also section 4 3 Preparations Follow the safety precautions that have been agreed with the operators With the service valve closed the pressure inside the retriever must be released Use the bleed off valve on the cylinder fig 9 To do this in a controllable manner a hose can be connected to the bleed off valve and a can should be used to catch the gas liquid which is bled off A hose for this purpose can be supplied by Metal Samples The bleed off valve should be left open as long as there is liquid coming out from the retriever This to get as much liquid as possible out of the retriever before it is being disconnected from th
14. D Metal sample Bi Hydraulic Retriever 4 Service Valve Operation amp Maintenance Manual Metal Samples A of Alabama Specialty Products Inc 152 Metal ie Rd PAL 36268 Phone 256 358 4202 Fax 256 358 4515 mail msc alspi com Internet www metalsamples com Index CHAPTER 1 Introduction 1 1 1 Conformity to the Pressure Equipment Directive PED sese 1 CHAPTER 2 Main ritieni eiii ide 2 2 1 Guarantee Restriction sss nennen eene sehn nnn enne 2 2 2 Tool Data Hydraulic 3 2 2 1 Hydraulic Retrieval Tools for Single Single Ball e Double Double Ball Isolation Service ValV8 11d 541444 54426 424441454 44414 4144444242444441424444444444444144424 eee ada e a Enna decia 4 2 3 Mei 5 CHAPTER Technical Description iii iia 6 3 1 Double Acting Hydraulic 6 CHAPTER 4 Operation Instruction 7 4 1 Important Safety Information eene 7 4 2 Operators Qualification eterne teen eene tne iater 8 4 8 Preparations AA AEs Sv at 9 4 4 Retrieval from a pressurized line
15. RING SEAL RING O RING 14 0x1 78 O RING 8 73x1 78 O RING 4 48x1 78 O RING 58 42x2 62 O RING 67 95x2 62 O RING 47 22x3 53 BACK UP RING SPIRAL 225 SLYDRING 055 O RING 40 87x3 53 BACK UP RING SPIRAL 223 SLYDRING 248 O RING 28 24x2 62 BACK UP RING ID28 WIPER ROD 0228 TURCON EXCLUDER O RING 29 82x2 62 O RING 32 99x2 62 BACK UP RING OD38 SLYDRING 238 Item 2 Repair Kit add to the Seal Kit the components that usually will require replacement after the retrieval tool has been used for a while such as Quick Couplings and Retriever Head Bolts as follows COMPRESSION RING BLEED VALVE 10 000 PSI QUICK COUPLING FEMALE JN 115 QUICK COUPLING MALE JN 115 PRESSURE GAUGE 0 600 C F Call Factory 33 6 2 Service Valve 6 2 1 Single Insulation Valve Under normal operating conditions the following spare parts are sufficient to keep the Single Isolation Service Valve in good operating condition Item Spare part Part Material 1 Seal Kit for Single Isolation Service C F Viton PTFE 2 Repair Kit for Single Isolation Service C F 3 Ball for Service Valve C F 17 4 PH Item 1 Seal Kit includes all elastomer seals O rings sliding rings special seals etc that are used in the Single Insulation Valve as per list below with P N O RING 59 5x3 00 O RING 18 64x3 53 O RING 79 5x3 00 O RING 84 5x3 00 O RING 55 25x2 62 O RING 4 48x1 78 BALL SEAT MAIN SEAL Item 2 Repair Kit add to the Seal Kit the compon
16. Service Valve will no longer be PED approved The tightening torque for the M12 bolts is 113 ft lbs 153 Nm Preservation If the Double Service Valve is to be stored after maintenance it should be preserved with a Multi Purpose Lubricant Make sure to select a type that also will drive out moisture and protect against corrosion 29 5 2 3 4 Manual hand operated Hydraulic Pump The hydraulic pump usually does not need any special maintenance However when the pump is to be stored for a while after a series of operations the following instructions should be followed Visual inspection Do a visual inspection of the pump and hoses and make sure that all parts are in good working condition Pay special attention to the following items e Hoses There shall be no visual damages to the outer sheet of the hoses e Quick connects These shall connect and disconnect easily and there shall be no damages externally or internally e Pressure gauge The gauge shall be undamaged and react immediately to increased pressure Change oil in the reservoir The hydraulic fluid should be replaced due to the possibility that it has been contaminated with moisture or other liquids gases from the pipeline that subsequently could cause corrosion attacks inside the pump Do as follows e Empty the tank completely e Fill up with new hydraulic fluid e Connect the hoses to the pump e Unscrew the quick connects from the free ends of the hos
17. access fitting is in 12 o clock position be aware of liquid that might flow out as the retriever is disconnected from the service valve If the access fitting is in 6 o clock position the retriever might still be filled with liquid and therefore after being disconnected it must be held in the same position until it can be emptied into e g a bucket IMPORTANT Make sure it is only the retriever that is loosened from the service valve and that the service valve still is kept properly tightened onto the access fitting Place the retriever with the opening up and set the pump to INSTALL Pump the plug probe assembly out of the retriever The probe and plug can now be inspected and serviced or replaced fig 10 Fig 10 4 5 Installation of a Monitoring Device into a Pressurized Pipe 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 Before starting the installation make sure that the retriever is clean and ready for use ref section 5 2 1 Routine inspection before use 1 Place the retriever with the opening upwards and connect the hoses from the pump Set the pump to INSTALL and pump until the connecting rod is extended 2 Mount the plug probe to the connecting rod Set the pump to RETRIEVE and pump until the probe has been fu
18. amples Double Acting Hydraulic Retriever and is not intended to provide the purchaser or user with information on the proper removal of probes in a pressurized system The procedures for probe removal in this manual are for illustrative purposes only Specific removal procedures must be developed by the tool owner or operator for each application As a minimum these procedures must address the safety of the tool operator and the technical effect on the operating system It is also necessary that the Approved Probe Removal Procedures are compared with the illustrative examples used in this Hydraulic Retriever Operation Manual to insure there are no conflicts between the examples and the Approved Probe Removal Procedures Do only use tools made of materials that will not produce sparks when used such as tools with plastic or brass surfaces When operating retrieval tools use approved personal safety tools like glasses gloves helmet shoes etc 4 2 Operators Qualification Operation of a retrieval tool on a pressurized system can be very dangerous and must only be attempted by properly trained personnel see section 5 6 using procedures approved by the owners of the operating system It is very important though that the hydraulic retriever should only be operated by people who fully understand how it works and are trained in its use Therefore it is not enough just to read this manual Operators should before working on any live pi
19. and tighten well grease the access fitting threads 43
20. as delivered The cases should be dry and clean on the inside before the equipment is being placed into them The equipment shall be stored indoors in a dry area 5 2 4 2 Maintenance during storage If the equipment has been preserved for storage as described in section 5 2 3 no additional maintenance during storage is required 31 CHAPTER 6 Spare Parts List All components which under normal operating conditions may require replacement due to destruction wear etc are noted in a separate spare parts list for the following type of equipment Double Acting Hydraulic Retriever Single Isolation Service Valve Double Isolation Service Valve Manual hand operated Hydraulic Pump Air driven Hydraulic Pump The spare parts lists include description with material specification if applicable Metal Samples Part No Metal Samples will normally have all recommended spare parts in stock 32 6 1 Double Acting Hydraulic Retriever Under normal operating conditions the following spare parts are sufficient to keep the Double Acting Retriever in good operating condition Item Spare part Part No Material 1 Seal Kit for Double Acting Hydraulic Retriever KR1015 Viton PTFE 2 Repair Kit for Double Acting Hydraulic Retriever Viton PTFE Item 1 Seal Kit includes all elastomer seals O rings sliding rings special seals etc that are used in the Double Acting Hydraulic Retriever as per list below with P N COMPRESSION
21. ce such operations must always be clarified with the operators before the job starts The following safety precautions should apply The operators control room must be told when the work starts and stops at each location e The operators control room are notified before bleeding of oil gas so they can by pass any gas detectors and stop hot work nearby during the bleeding 4 4 Retrieval from a pressurized line 1 Make sure that there is enough space available to use the retriever Also make sure that the size of the hydraulic retriever is sufficient for the actual probe length at the selected location See tables in section 2 1 1 2 Confirm the pipeline pressure and whether variations in pressure can be expected during the period when the hydraulic retriever is to be operated 3 Check the hydraulic access fitting including 1 Check that the cover is sufficiently tightened 2 Unscrew the locking pins for inspection one at a time 3 Check the O rings for cuts and wear and replace them if necessary 4 Inspect and if necessary clean the hole in the access fitting especially the surface for the O rings fig 3 4 Make sure the locking pins are sufficiently tightened after inspection 5 Remove the pipe plug or if a continuous monitoring cable is connected remove the cable from fitting Locking pin O rings Cable assy if applicable Fig 3 6 Remove the protective cover Check for leaks around the plug
22. e service valve WARNING When bleeding off sour gas or other dangerous gases fluids a hose must bleed off valve be used and every precaution possible must be taken to ensure that the operators are not endangered The procedure for bleeding off dangerous substances will be different for different situations and therefore this manual cannot give any detailed description of such an operation If in doubt contact your supplier for further advice 23 With the pressure in the retriever reduced to 0 it must be checked that the service valve is sealing properly This can be done by closing the bleed off valve and leaving it closed for 1 2 minutes Then open it again to see if there has been any pressure build up inside the retriever If the service valve leaks then check if it is properly closed Also check that the by pass valve is closed If leaks in the valve cannot be stopped the plug probe must be reinstalled see installation procedure section 4 5 step 7 12 and the valve must be serviced For systems containing high pressure dry gas it can be difficult to make the Service Valve to seal properly after the plug probe has been retrieved This is because it is difficult to reduce the pressure in the retriever quickly enough through the bleed valve to create the difference in pressure that is required to force the ball against its seat To assist in creating this difference in pressure the retriever can be utilized by
23. ection with diameter 1 1 28 mm Slide the tapered end of the shaft carefully into the wiper and push the calibrator into the inner barrel until it stops Keep it in this position for 2 3 minutes The internal wiper is now ready for use 26 Preservation If the retrieval tool is to be stored after maintenance it should be preserved with a Multi Purpose Lubricant Make sure to select a type that also will drive out moisture and protect against corrosion 5 2 3 2 Single Isolation Service Valve 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 liquids a daily cleaning might be sufficient After each use check if the valve can easily be opened closed If the rotation of the ball is obstructed by dirt it must be cleaned For quick cleaning compressed air can be blown 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 pr
24. ely certain that all threaded surfaces are cleaned from particles sand metal particles etc and properly lubricated before any of the parts are mounted together This is especially important when mounting the union thread adapter to the main cylinder Use a high quality anti seize lubricant e g Copaslip Molyslip or similar types After all seals have been installed on the correct locations use O ring grease to lubricate the seals especially before the connecting rod is installed into the inner barrel before the inner barrel is installed into the main cylinder and before the union thread adapter is installed on the main cylinder Be careful when putting the parts back together Special care should be taken to ensure that the seals are not damaged when the components are assembled 24 If the quick couplings 40 41 are removed from the main cylinder for maintenance or replacement make sure that they are reinstalled in correct positions The female one shall be installed on the retriever head while the male one shall be installed on the middle of the retriever main cylinder IMPORTANT If the bolts for the retriever head are to be replaced always replace them with new original bolts from Metal Samples If other types of bolts are used the Double Acting Hydraulic Retriever will no longer be PED approved The tightening torque for the M16 bolts on the retriever head is 113 ft Ibs 153 Nm 25 Replacement of wiper rings T
25. ents that usually will require replacement after the retrieval tool has been used for a while such as ball valve needle valve etc as follows 2 BALL VALVE NEEDLE VALVE SERIE 6000 SEAL CARRIER BY PASS STEM PIN 5X50 Item 3 Ball might need replacement if the Service Valve is used on systems with large amounts of sand or other particles that might cause scratches or other damages to the surface of the Ball Such damages might cause minor leaks when the Valve is used on gas systems Please note that the Ball is also included in the Repair Kit C F Call Factory 34 6 2 2 Double Insulation Valve Under normal operating conditions the following spare parts are sufficient to keep the Double Isolation Service Valve in good operating condition Spare part Seal Kit for Double Isolation Service Ball for Service Valve Not2 2 pieces for each double valve Item 1 Seal Kit includes all elastomer seals O rings sliding rings special seals etc that are used in the Single Insulation Valve as per list below with P N O RING 59 5x3 00 O RING 18 64x3 53 O RING 79 5 3 00 O RING 84 5x3 00 O RING 55 25x2 62 O RING 4 48x1 78 BALL SEAT MAIN SEAL to note that the quantity are two for each item except for O ring 59 5x3 00 that remain one Item 2 Repair Kit add to the Seal Kit the components that usually will require replacement after the retrieval tool has been used for a while such as ball valve needle valve etc
26. es e Pump 10 20 strokes in both retrieve and install mode and make sure that new hydraulic fluid is flowing out through both hoses Put the quick connects back on the hoses If any further maintenance or repair should be required replacement of seals etc instructions for this is described in the Repair Parts Sheet which is delivered with the pump For any further maintenance or spare parts please refer to the pump manufacturer directly 5 2 3 5 Air operated Hydraulic Pump Basic operation and maintenance of the air operated pump is described the Instruction Sheet which is included in the retriever kit If any further maintenance or repair should be required replacement of seals etc instructions for this is described in the Repair Parts Sheet which is delivered with the pump For any further maintenance or spare parts please refers to the pump manufacturer directly 30 5 2 4 Storing preservation and maintenance of preservation 5 2 4 1 Preservation and storage Preservation As described in section 5 2 3 if the retrieval tool and or service valve is to be stored for a while after maintenance the equipment should be preserved with a Multi Purpose Lubricant Make sure to select a type that also will drive out moisture and protect against corrosion Storage After the equipment has been properly cleaned maintained and preserved ref section 5 2 3 it should be stored in the original transport cases in which it w
27. fitting is present and undamaged 5 2 2 Periodic Maintenance There is no regular periodic maintenance based on time of use or number of operations of this equipment The need for periodic maintenance will depend on the conditions under which the equipment is being used If the retriever is used on pipe systems containing large amounts of sand or other debris it may be necessary to go through the maintenance routine quite frequently to keep the retriever sufficiently clean during operations In severe cases with e g lots of sand in the pipe system it might be required to clean the retriever after each single retrieval operation This is in order to avoid high wear and or other damages to the internals of the retriever To perform periodic cleaning follow the instructions in section 5 2 3 1 Disassembly and cleaning 5 2 3 Maintenance After Use When series of retrieval operations are completed and the hydraulic retriever is to be stored for a while it should be disassembled cleaned and checked following the procedure below 5 2 3 1 Double Acting Hydraulic Retriever Before starting make sure to have cleaning rugs a can and a stick of wood or another non metallic material of approx the same length as the retrieval tool available Disassembly and cleaning 1 Connect the hoses from the pump Set the pump to RETRIEVE and pump until the inner barrel 3 and connecting rod 4 is fully retracted into the retriever
28. following spare parts are sufficient to keep the Manual Hydraulic Pump in good operating condition Item Spare part Part No Material 1 Repair Kit for Air driven Hydraulic Pump SEE PUMP MANUFACTURER 2 Hydraulic Hose with Quick coupling installation side 3 Hydraulic Hose with Quick coupling retrieve side Item 1 Repair Kit includes all seals and other components that usually will require replacement when the pump is to be overhauled Ask directly to pump manufacturer Item 2 and 3 Hydraulic Hoses with Quick Couplings shall always be replaced if there are visible damages in the outer sheet of the hose The Quick Couplings are different on the two hoses to avoid the hoses from being incorrectly connected so please make sure to order the correct hose C F Call Factory 36 7 1 Double Acting Hydraulic Retriever 7 1 1 General Arrangement Drawing with Part List CHAPTER 7 Drawings TTD 2 27223 222222222224 22222222222222222 22222222 93955 3p foumax 7 1 2 Detail for Seals on rear section of Retriever YA SSS 38 7 1 4 Detail for Seals on front section of Retriever YA P L LIS I ZA NS N 72 22 LA S H amp 17 2 7 Uu 39 7 2 Single Isolation Service Valve 7 2 1 General Arrangement Drawin
29. g with Part List 8 p mm 72 j P gt 3 5 __ 1 ii 15 Screw tS 0 5 7 3 Double Isolation Service Valve 7 3 1 General Arrangement Drawing with Part List ZA uh 41 CHAPTER 8 Sequence of Operations DOUBLE ACTING HYDRAULIC RETRIEVER TOOL PRELIMINARY PRECAUTIONS Check if maintenance of retrieval tool service valve and pump has been properly carried out Make a trial in the workshop to ensure that all parts are in good working conditions Check the threads by screwing the service valve onto the retrieval tool amp onto the access fitting Check the oil level in the pump The quantity of hydraulic oil in the pump and in the retrieval tool must not exceed the quantity required and indicated in the manual of the pump Check that the line pressure is compatible with the one indicated in this manual Check the dimension of the probe to retrieve to ensure that the retriever model is suitable for operations RETRIEVAL OPERATIONS 1 Remove the cover slowly If any leaks occur retighten the cover well then check if the locking pins and o rings are clean and well tighten then repeat operation If leaks insist then retighten the cover and advise the control room for check during shut down 2 Connect hoses from pump to retriever Open the retriever head valve 4 Setpump to install and pump until connecting rod is fully extended and pressure reaches approx 725 psi 50 bar
30. he hydraulic access fitting Lubricate them properly fig 14 16 Puton the heavy duty protective cover Tighten with a 4 134 105 mm spanner or a suitable pipe wrench This will take the load off the locking pins fig 14 17 Reinstall the pipe plug or continuous monitoring cable if applicable fig 14 Fig 14 EN 4 6 Training program for Operators Only specially trained personnel should attempt to operate the Double Acting Hydraulic Retriever 20 CHAPTER 5 Maintenance 5 1 General 5 1 1 Introduction A Proper and regular maintenance is very important in order to ensure trouble free operation of the Double Acting Hydraulic Retrieval Tool and to keep it in good operating condition over a long period of time 5 2 Maintenance instructions 5 2 1 Routine Inspections before use After a storage period the retriever must be checked to ensure that it is in operational condition before being used The check points described in this section assume the retriever has been properly cleaned and maintained after its last use If in doubt follow the maintenance instructions in section 5 2 3 instead If the retriever is to be used over a period of several days this check should also be performed daily before the first retrieval operation 5 2 1 1 Double Acting Hydraulic Retriever Check that all parts are present and that they are clean and undamaged Check the internal seals as follows Connect both hoses from t
31. he hydraulic retriever has one wiper ring installed on the inner barrel When this wiper rings is damaged and need to be replaced the following instructions should be followed Please note that new wiper ring will be a lot easier to install and form to shape if it are heated first Heating shall be done by keeping the wiper ring in boiling water for a few minutes Do NOT attempt to heat the wipers in any other way Internal wiper see figure 15 e drawing in section 7 1 3 1 Make sure a new wiper of correct type is available The Internal wiper 33 is installed together with an O ring 34 in a common groove 2 Remove the old wiper from the groove by use of i e a small screwdriver 3 Remove the O ring which is installed in the same groove under the wiper 4 Clean the groove properly 5 Install a new O ring into the groove and place it in the groove as shown on the drawing 6 Form the wiper into a kidney shape without creating any sharp bends fig 15 7 Place the deformed wiper in the groove over the O ring and make sure the orientation is correct with the pointed cleaning side of the wiper facing out of the inner barrel as per fig 15 8 With the wiper placed in the groove reform it back to its original shape first by use of a finger or a small round object When the wiper is roughly formed to shape in the groove final shape calibration shall be done i e by use of the Glydring Calibrator This calibrator has a shaft s
32. he pump to the retriever Set the pump to INSTALL and start pumping The rod shall extend with a smooth and even movement Continue to pump until the rod is fully extended and the pressure gauge on the pump shows 1450 psi 100 bar Leave the pressure on for 1 2 minutes to see that it stabilizes and does not drop significantly Set the pump to RETRIEVE and pump until the connecting rod is fully retracted The rod should retract with a smooth and even movement Continue to pump until the pressure gauge on the pump shows 1450 psi 100 bar Leave the pressure on for 1 2 minutes to see that it stabilizes and does not drop significantly If the pressure drops more than 290 435 psi 20 30 bar in any of the above described steps the internal seals must be checked and replaced if necessary Follow the instructions in section 5 2 3 21 Check that the O ring on the union thread adaptor for sealing against the service valve is present and undamaged 22 5 2 1 2 Service Valve Check that all parts are present especially the bolts connecting the valve sections together Check that the service valve is clean and undamaged both externally and internally Check that the service valve can be opened and closed easily Check that there are no deep scratches or other damages in the surface of the Ball s Minor scratches will usually not cause any problems Check that the O ring in the bottom end for sealing against the access
33. is tool on traditional 2 mechanical Access Fittings with 3 ACME threads if the 2 fitting has been equipped with a Hydraulic Access Fitting Adapter The Hydraulic Access Fittings Access Fitting Adapters do not have internal threads Instead the retrievable parts are kept in position by use of locking pins and heavy duty covers The Double Acting Hydraulic Retriever is designed to be lightweight and compact in size and this makes it safer and easier to operate and can also make it possible to monitor locations which otherwise would be inaccessible due to the size of traditional mechanical retrieval tools The main components of the retrieval tool is made in stainless steel which makes it easy to maintain and should ensure a long service life The Double Acting Hydraulic Retriever is operated by either a manual hydraulic pump or an air driven hydraulic pump When the Hydraulic Retriever is used on a pressurized system the pipeline pressure alone will normally provide sufficient force for retrieval of the monitoring equipment from the access fitting and into the retriever When monitoring equipment is to be installed 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 CHAPTER 4 Operation Instruction 4 1 Important Safety Information This Manual has been prepared to provide technical information on the operation of the Metal S
34. lly retracted into the retriever fig 11 Fig 11 3 Lift the retriever onto the service valve screw the hammer nut on to the valve and tighten it 4 Set the pump to INSTALL 5 Balance pressures on both sides of the service valve by for standard service valves slowly open its by pass valve The pressure in the retriever will now increase until it equals the line pressure The pressure can be read on the retriever pressure gauge for double isolation service valves slowly open the by pass valve for the upper ball closest to the retriever and then open the upper ball itself Normally there will be no pressure behind this ball but it should be opened carefully anyway in case there is a leak past the lower ball Now slowly open the bypass valve for the lower ball The pressure in the retriever will now increase to line pressure If the pressures cannot be balanced most likely due to dirt in the by pass valve it will be difficult to open the service valve especially when the line pressure is high above 725 psi 50 bar The pressure should then be balanced by use of the pump To balance the pressures with the pump use the following steps e Setthe pump to RETRIEVE and pump until the probe is fully retrieved e Install the Back Pressure Quick Coupling Assy NOT included in the retriever Kit on the Bleed off Valve e Disconnect the hose from the female quick coupling on the middle of the retriever and
35. n used with clean liquids a daily cleaning might be sufficient After each use check if the valve can easily be opened closed If the rotation of the ball is obstructed by dirt it must be cleaned For quick cleaning compressed air can be blown 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 Disassembly and cleaning See also drawings and parts list in section 7 2 and 7 3 Numbers in indicate pos nos in parts list 1 Remove the handle 21 24 2 Loosen the six bolts M12x120 15 and remove the end section 14 3 Rotate the stem 5 of the upper body 25 to closed position and then remove the ball Remove the Seeger 16 Remove the stop ring 6 Push the stem 5 into the upper body 25 Repeat steps 3 6 for main body 1 O 0 A 8 If the main seals 11 needs replacement then unscrew the seal carriers 12 9 Unscrew and remove the by pass stem 17 10 Check and eventually replace the by pass stem O ring 19 IMPORTANT If the bolts for the Service Valve Body are to be replaced always replace them with new original bolts from Metal Samples If other types of bolts are used the
36. ng temperature 446 230 Hydraulic test pressure 9135 psi 630 bar The Double Acting Hydraulic Retrieval Tool and Service Valve Single amp Double Ball are PED approved 2 2 1 Hydraulic Retrieval Tools for Single Single Ball and Double Double Ball Isolation Service Valve The following Double Acting Hydraulic Retrieval Tool Kits are for exclusive use with Single Isolation Service Valve Retrieval Max Cylinder Max retrievable Part Number length probe length HA10401 1 19 9 in 505 mm 5 1 in 130 mm HA104021 24 0 in 610 mm 7 9 in 200 mm HA104031 30 0 in 760 mm 11 8 in 300 mm HA104041 35 8 in 910 mm 15 8 in 400 mm HA104051 41 7 in 1060 mm 19 7 in 500 mm HA104061 47 6 in 1210 mm 23 6 in 600 mm HA104071 53 5 in 1360 mm 27 6 in 700 mm HA104081 59 5 in 1510 mm 31 5 in 800 mm HA104091 65 4 in 1660 mm 35 4 in 900 mm 104101 71 3 in 1810 mm 39 4 in 1000 mm The following Double Acting Hydraulic Retrieval Tool Kits are for exclusive use with Double Isolation Service Valve Retrieval Max Cylinder Max retrievable Part Number length probe length HA104012 28 2 in 717 mm 9 0 in 230 mm HA104022 32 4 in 822 mm 11 8 in 300 mm HA104032 38 3 in 972 mm 15 8 in 400 mm HA104042 44 2 in 1122 mm 19 7 in 500 mm HA104052 50 1 in 1272 mm 23 6 in 600 mm HA104062 56 0 in 1422 mm 27 6 in 700 mm
37. onnecting rod into the service valve and mate the threads on the rod and the plug together Screw the rod into the plug by rotating the retriever Screw until the rotation suddenly stops Do not tighten fig 7 Connect again the hoses from the pump and set the pump to RETRIEVE Open the head valve and pump 1 2 strokes on the hand air pump This will pull the retriever towards the end face of the service valve Connect the hammer nut to the service valve and screw until it stops Then tighten the hammer nut by use of the plastic hammer fig 7 Check that the bleed off valve on the retriever is closed service valve 16 Set the pump to INSTALL and pump until the pressure in the retriever is at least 435 725 psi 30 50 bar higher than the pressure inside the pipeline If it is difficult to determine the exact pipeline pressure the pressure should be increased to an even higher level 725 1450 psi 50 100 bar above expected pressure in the pipeline 17 Loosen counter clockwise all of the locking pins in the access fitting The locking pins should be easy to loosen If they are difficult to loosen high friction the pressure in the cylinder might be too low The pins must then be tightened again and the pressure increased see step 16 before the pins are loosened again IMPORTANT The locking pins should only be screwed out until the head of the pin is flush with the outside of the access fitting No threads mu
38. operly as described in the following instructions Disassembly and cleaning See also drawings and parts list in section 7 2 and 7 3 Numbers in indicate pos nos in parts list 1 Remove the handle 21 24 2 Loosen the six bolts M12x40 15 and remove the end section 14 Rotate the stem 5 to closed position and then remove the ball 4 Remove the Seeger 16 Remove the stop ring 6 Push the stem 5 into the main body 1 O a fF 7 If the main seal 11 needs replacement then unscrew the seal carrier 12 8 Unscrew and remove the by pass stem 17 9 Check and eventually replace the by pass stem O ring 19 IMPORTANT If the bolts for the Service Valve Body are to be replaced always replace them with new original bolts from Metal Samples If other types of bolts are used the Service Valve will no longer be PED approved The tightening torque for the M12 bolts is 113 ft Ibs 153 Nm Preservation If the Service Valve is to be stored after maintenance it should be preserved with a Multi Purpose Lubricant Make sure to select a type that also will drive out moisture and protect against corrosion 28 5 2 3 3 Double Isolation Service Valve 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 whe
39. pe System be sufficiently trained by qualified instructors Operators should also be familiar with the different components that are used with the hydraulic access fittings e g Hollow and Solid Plugs Locking Pins Hydraulic Covers and the different types of seals used on these parts 4 3 Preparations The procedure in section 4 4 describes step by step how to operate the Metal Samples Double Acting Hydraulic Retriever in order to perform the retrieval of a monitoring device e g a corrosion probe installed on a pressurized pipeline and subsequent reinstallation of the monitoring device The procedure covers use of the Double Acting Hydraulic Retriever with both the standard Service Valve and the Double Isolation Service Valve Where there are differences in the operation of the two valve types this is specified throughout the procedure Before the retriever is used it must be checked to insure that all parts are in good operating condition See section 5 2 1 Routine inspection before use Before the air pump is used please read the instruction sheet that is delivered with the pump Before work commences on a specific location this must be clarified with the operators responsible for the area pipe system where the fitting is installed Use of the Hydraulic Retriever involves bleeding of pressurized fluid gas from the pipe System If the pipe system contains hydrocarbons bleeding of liquid gas might trigger gas detectors hen
40. pumping in RETRIEVE mode as this will increase the volume inside the retriever If the plug probe has been fully retrieved already the pump must be set to INSTALL and the plug probe pumped towards the ball in the service Valve Be very carefully during this pumping to avoid having the probe coming in contact with the ball as this might damage both the probe and the ball Watch the pressure gauge carefully and stop pumping immediately as soon as the pressure starts to increase Open the bleed valve on the retriever set the pump back to RETRIEVE and pump as fast as possible This will cause the pressure drop in the retriever and should be sufficient to make the ball seal against its seat 24 25 26 If the gas still cannot be bled off then close the bleed off valve Pump the plug back into the access fitting tighten locking pins remove the service valve and perform maintenance on the service valve check the ball and sealing seats for scrape marks For double isolation valves only When the lower ball is closed and it is sealing properly close the upper ball To utilize the added safety of the double isolation valve it is important to verify the function of the lower ball before upper ball is closed Provided the service valve is sealing properly the retriever can now be disconnected from the valve Loosen the hammer nut and unscrew it from the valve Then lift the retriever away from the service valve If the
41. r and Service Valve e does the media in the pipe represent a hazard to the operators if they come into contact with it If any of the above described issues or others that might have been identified during the evaluation are considered to represent a hazard which cannot be compensated properly for by safety precautions then the retriever operation should not be performed under full line pressure CHAPTER 3 Technical Description 3 1 Double Acting Hydraulic Retriever Equipment for internal corrosion monitoring can be i e corrosion probes weight loss coupons and bio probes are normally installed in access fittings of which there are many types which have been installed on the pipe vessel A special version of the access fittings T type fittings can also be used for installation of equipment for injection of chemicals or sampling of the contents in the pipe The Double Acting Hydraulic Retriever is a tool which is designed for servicing all kinds of equipment that can be installed into access fittings With the Double Acting Hydraulic Retriever equipment can be installed into or retrieved from access fittings while the pipe system is in normal operation i e under full operational pressure The standard Double Acting Hydraulic Retriever has a pressure rating of 6090 psi 420 bar and is PED approved The Double Acting Hydraulic Retriever is designed to be used only on Hydraulic Access Fittings However it is also possible to use th
42. st be visible the pins are unscrewed too far they will leak when the plug is retrieved fig 8 Loosen locking pins until head of pins are flush with outside of access fitting lw Fig 8 18 Check that the service valve is fully opened On the double isolation service valve both balls must be fully opened 19 Make sure that the bleed valve on the retriever is closed For hand pump Set the pump to RETRIEVE Then release the cylinder pressure by pumping one stroke on the pump For air pump Move the handle quickly from INSTALL to RETRIEVE and avoid stopping in the center position Handle in center position will allow a quicker than desired retrieval of the plug probe If the pipeline contains gas at a pressure above 2900 psi 200 bar the following can be done to control the pressure drop in the retriever Close the head valve on the retriever before setting the pump to RETRIEVE With the handle in RETRIEVE position the pressure in the retriever can be released slowly by opening the head valve Concerning the pressure in the line to fully retrieve the plug probe use the hand airpump and keep pumping until the pressure gauge on the pump shows that pressure is starting to build up inside the retriever Normally 25 50 strokes depending on retriever size This indicates that the probe is fully retrieved Check for leaks around the locking pins If leaks do occur the probe must be reinstalled see step 7 11 in
43. t sealing properly in the access fitting If this happens use the pump to increase the retriever pressure to a level at least 1450 psi 100 bar above pipeline pressure Then loosen the locking pins and re tighten them Check again if the leaks are still there If so the plug must be pulled out for inspection replacement of the primary packing See instruction for retrieval section 4 4 step 17 25 12 Providing no leaks occur the retriever can be removed Loosen the hammer nut and unscrew it completely from the service valve Be aware of fluid that might flow out when the retriever is being disconnected Set the pump to INSTALL and pump until the connecting rod is fully extended Continue to pump until the gauge on the pump shows that the pressure inside the retriever is at least 290 psi 20 bar Then close the retriever head valve and release the pressure in the pump hose Disconnect the hoses from the retriever and then unscrew the retriever connecting rod from the plug by rotating the retriever 13 Use the hammer to loosen the service valve from the hydraulic access fitting Remove the valve 14 Clean the end of the plug and especially the hole where the connecting rod was mounted Remove all dirt and moisture carefully NOTE If a probe with an electrical connector has been installed the probe connector must be cleaned thoroughly with a cleansing agent suitable for electrical equipment 15 Check external threads on t
44. the installation procedure of section 4 5 Reinstall cover and recheck the O rings on the locking pins IMPORTANT When using the pump is in RETRIEVE position the pressure should never exceed 1450 psi 100 bar see gauge on pump This is because if the probe for some reason should be prevented from moving out of the fitting attempting to retrieve it at a higher pressure might cause damages to the plug or to the retriever If the plug probe cannot be retrieved at 1450 psi 100 bar it should be left inside the fitting until the next shut down 20 Close the service valve If a double isolation valve is used at this stage close only the lower ball closest to the access fitting 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 There are large amounts of sand debris inside the valve hampering the rotation of the ball e The probe is not fully retrieved The probe is fully retrieved but the probe length exceeds the capacity of the retriever To make sure that the probe is fully retrieved pump some additional strokes on the pump and check that the pressure inside the retriever increases for each stroke and stabilizes at the higher level If necessary keep pumping until such stabilization is achieved If the valve still cannot be closed the probe must be installed again see installation procedure section 4 5 step 7 1

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