User Manual Lift/Test Cap 180-2192-HV0
Contents
1. Description Rev A 16 Oct 2008 Initial Issue Rev B 26 May 2009 Modified with Angled NPT Port OPS 2192 Rev B User Manual Phuel Lift Test Cap Qu 180 2192 HVO Safety WARNING Trapped air requires considerable time to compress and when it is compressed is highly dangerous lt 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 This equipment and the equipment it is attached to is heavy never position yourself below a suspended load OPS 2192 Rev B iii User Manual Phuel Lift Test Cap OIL TOOLS 1 80 21 92 HVO 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 Product 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 inspect2. Test cap to blank off open end of equipment under test 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 O ring is 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 O ring for seating and signs of damage replace if required with appropriate item from redress kit e Ensure threads are clean OPS 2192 Rev B 3 User Manual Phuel Lift Test Cap Que 180 2192 HVO 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
3. Phu Unit 17 Denmore Industrial Estate Denmore Road Bridge of Don Aberdeen AB23 8JW User Manual Lift Test Cap 180 2192 HVO OPS 2192 Rev B User Manual Phuel Lift Test Cap Que 180 2192 HVO Table of Contents Revision HIStory mM ii SE iii 1 cios eio 1 1 1 1 7 MENO 1 1 2 Product Identification uuesic persi een paran na bond ven Fan bna d qa de ko gena onu bikes 6a la 1 2 Technical Specification sido URS a esae d ani pepe nep E SR iris adu 2 3 Technical Description EE 3 2 Op mn 3 4 1 Fela 3 42 E iso EE 3 4 3 Post IO RTT 3 ENTEN 4 5 1 all gere NT e 110 EEN 4 SEE 010 EE 4 5 2 1 Pre FN 4 522 Monthly conen gninnan iai 4 DES 450210 JE EE eee ee ee eee 4 5 2 4 Five Yearly E 4 SEE eee 5 DA lt EE 5 55 Redress e lt 5 5 5 1 BES ASSEMBIY PE EEE 5 le 5 5 6 Maintenance Record Sheet cccccsssccccccessecececeeseeeeeeeeseeeeeeaaaeees 6 EE ERE EE ere eee EE 7 7 Parts List and Drawings EE 8 coc c pe 10 8 1 1 Individual TE 10 Tablet Technical Dele WEEN 2 Table 2 Maintenance Record e ea E rk i rk xis 6 Table PU MIRROR ROREM 8 Table 4 Redress Kit Part No RDK 2192 HVO esee 10 Fig re d Eu RK EE 2 Figure 2 Lift Test Cap Assembly saccicoctccsscncinscicertectscerangeadeiecrnceesepeadsceciceecenss 9 OPS 2192 Rev B i Ewe User Manual Lift Test Cap 180 2192 HVO Revision History Issue Release Date
4. id and dry Remove test caps Apply coating of de watering solution to protect the bore and threads Fit thread protectors On completion of all maintenance ensure the maintenance record sheet Para 5 6 is completed OPS 2192 Rev B User Manual a Phuel Lift Test Cap Que 180 2192 HVO 7 Parts List and Drawings Item Number Part Number Quantity Description 1 180 2093 480 1 LIFT TEST CAP 11 5 2 125 2098 480 1 COLLAR 11 5 4 ACME 3 180 2193 STL 1 EXTERNAL CIRCLIP SH 975 4 1801 0444 V90 1 O Ring B S Size 444 5 915 2152 STL 1 Crosby Bolt Type Shackle 12 Tonne SWL 6 900 2752 316 1 1 NPT Hollow Hex Plug 100 910 2153 N66 1 11 1 2 4 TPI ACME MALE PROTECTOR Table 3 Parts List Note Thread Protector item 100 not shown in assembly drawing Figure 2 OPS 2192 Rev B 8 User Manual Phuel Lift Test Cap Aue 180 2192 HVO SW 77 pt Figure 2 Lift Test Cap Assembly OPS 2192 Rev B User Manual Phuel Lift Test Cap Qu 180 2192 HVO 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 Part Number Comments 801 0444 V90 Quantity Description O R
5. ing B S Size 444 Table 4 Redress Kit Part No RDK 2192 HVO 8 1 1 Individual Items Individual items may be ordered as required using the part number specified Note O Rings conform to industry standards and may be substituted with those from other suppliers at the sole risk of the user OPS 2192 Rev B 10
6. ion 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 CUSTOMER ID No PHUEL ID No 06 XXX XX MWP amp SERVICE TEST DATE OPS 2192 Rev B 1 7 Phuel o TOOLS User Manual Lift Test Cap 180 2192 HVO 2 Technical Specification Part Number 180 2192 HHO Connection 11 7 4 Otis Type Vo NPT Maximum Working Pressure MWP 10 000 Psi Working Load Limit WLL 12 Tonne Height 11 93 Diameter 13 Weight 197 lbs Service H2S Table 1 Technical Data Figure 1 Lift Test Cap OPS 2192 Rev B User Manual Ph el Lift Test Cap Que 180 2192 HVO 3 Technical Description The Lift Test cap is used in conjunction with other equipment to allow the pressure testing and lifting of various components It is used to blank off the equipment and also allow the bleeding off of air during the set up procedure for testing 4 Operation All operations to be carried out by suitably qualified and competent personnel e Attach Lift
7. to Section 4 1 and Section 4 3 for details 5 2 2 6 Monthly e Carry out a thorough inspection of the Lift Test Cap and Shackle reporting any signs of defect 5 2 3 Yearly e Disassemble Lift Test Cap see 5 5 1 clean and degrease all components e Inspect the condition of all sealing surfaces and surface coatings e Re coat threads and sealing surfaces if necessary If in doubt contact Phuel Oil Tools Ltd e Replace all elastomeric seals with items from redress kit see spares Table 4 e Regrease components e Re assemble see 5 5 2 e Pressure test to maximum working pressure in accordance to testing procedure see 6 Inspect paint work and repair as necessary 5 2 4 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 2192 Rev B 4 User Manual Phuel Lift Test Cap Que 180 2192 HVO 5 3 Safety e Many of the components are heavy and should not be lifted without lifting aids e Ensure all pressure testing is carried out in the appropriate testing area by suitably qualified personnel e Wear appropriate personal protective equipment e Do not over exert yourself while using torque wrenches Use appropriate mechanical advantages when available e Ensure that all tools and equipment are in good condition and are suitable for the intended use e Clear up any fluid spills immediatel
8. y to avoid slips 5 4 Tools The following tools are required e Circlip Pliers e Wire Brush 5 5 Redress Procedure 5 5 1 Dis Assembly e Remove circlip and remove collar e Remove O ring and discard 5 5 2 Re Assembly e Fit O ring to test cap e Place collar over test cap and hold in place using circlip OPS 2192 Rev B 5 g Phuel User Manual Lift Test Cap 180 2192 HVO 5 6 Maintenance Record Sheet Date Type of Performed Verified Comments Performed Maintenance By By Table 2 Maintenance Record OPS 2192 Rev B 6 User Manual 3 Phuel Lift Test Cap OIL TOOLS 1 80 21 92 HVO 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 10 000 psi 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 flu
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