Emerson Roxar 6000 ps User manual

Document no. / rev.: ROX000337352/AE
ttt
USER MANUAL
Roxar Hydraulic
Retrieval Tool

User Manual
Document no. / rev.: ROX000337352_AE
Hydraulic Retrieval Tool
2
TABLE OF CONTENTS:
1
1.Introduction ....................................................................................................................................... 3
1.1Disclaimer .................................................................................................................................. 3
1.2Purpose and scope .................................................................................................................... 3
1.3Warnings ................................................................................................................................... 3
1.4Personnel safety and HSE ........................................................................................................ 4
1.5Operator training ........................................................................................................................ 5
1.6Contact information ................................................................................................................... 5
1.7Product support ......................................................................................................................... 5
2.HRT system Components ................................................................................................................. 6
Figure 1: Hydraulic retriever and service valve .................................................................................... 6
2.1Hydraulic Retriever .................................................................................................................... 6
2.2Service Valve ............................................................................................................................. 8
2.3Hydraulic Access Fitting ............................................................................................................ 8
2.4Air / Hand pump ......................................................................................................................... 9
2.5Tools list .................................................................................................................................... 9
3.OPERATION ................................................................................................................................... 11
3.1Personnel qualifications ........................................................................................................... 11
3.2HSE ......................................................................................................................................... 11
3.3Preparations (pre job) .............................................................................................................. 12
3.4Access fitting Inspection & Preparation ................................................................................... 13
3.5Online Retrieval of Device ....................................................................................................... 14
3.6Online Installation of Device .................................................................................................... 20
3.7Troubleshooting Guide ............................................................................................................ 23
3.8Retrieval Checklist ................................................................................................................... 25
4.Maintenance ................................................................................................................................... 29
4.1Routine inspection before use ................................................................................................. 29
4.2Routine Maintenace ................................................................................................................. 30
4.3Maintenance when in use ........................................................................................................ 30
4.4Maintenance after use ............................................................................................................. 30
4.4.1Hydraulic Retriever ........................................................................................................... 31
4.4.2Service Valve ................................................................................................................... 32
4.5Biennial Inspection .................................................................................................................. 33
4.6Spare parts .............................................................................................................................. 33
4.7Storing and Preservation ......................................................................................................... 34
5.Attachements .................................................................................................................................. 34

User Manual
Document no. / rev.: ROX000337352_AE
Hydraulic Retrieval Tool
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1. INTRODUCTION
1.1 Disclaimer
This document or any part of its content can not be reproduced or distributed in any way or means for
any purpose without the written approval from Roxar Flow Measurements AS. The document is under
Emerson Electric copyright protection ©2016 Emerson Electric Co. All rights reserved.
1.2 Purpose and scope
Roxar provides safe and high quality products and services to meet the demands and requirements
from our clients. As part of this approach we are issuing user manuals and work instructions like this
document to ensure that all activities related to installation and operation of Roxar equipment is
performed in a safe and reliable manner.
The purpose of this user manual is to ensure a good understanding on how the Hydraulic Retrieval
Tool kit is operated and maintained. This user manual also describes how the retrieval operation is
performed on pressurized systems, with focus on the safety aspect of the operation. It is crucial that a
retrieval tool operator has the required competency and up-front training needed to perform this work
safely.
This user manual describes any work performed from a strictly general point of view so any particular
application, installation or process needs to be evaluated as specific cases and adapted to under the
responsibility of the operator. If there is any need for further clarifications, please contact your regional
Roxar/Emerson representative.
In this user manual, the following products are covered:
 Hydraulic Retrieval Tool (both versions: 6000psi and 10000psi)
 Service Valve (both versions: 6000psi and 10000psi)
 Air / Hand Pressure Pump
For details on mechanical access fittings, covers and plugs, reference is made to the Hydraulic Access
System User Manual which should be consulted for more detailed understanding of the access system
main components (access fitting, plug and cover).
1.3 Warnings
Instructions and procedures in this document may require special precautions to ensure the safety of
the personnel performing the operations. Information that potentially raises safety issues is indicated by
a warning symbol followed by a safety message:
With a detailed Safet
y
Messa
g
e
Before any operation or work preceded by the warning is initiated it is important that the safety
messa
g
e
(
s
)
are understood and full
y
adhered to.

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Personnel safety and HSE
It's important that any recommendation or safety advice is followed to ensure safe operations.
1. Roxar Online Hydraulic Retrieval Operations Risk Assessment must be used and followed in
conjunction with this document when performing all online hydraulic retrieval operations.
2. Two Roxar certified and experienced operators are required to perform online hydraulic retrieval
operations at all times.
3. Do not attempt to use any hydraulic retrieval equipment unless you have been properly trained
and deemed competent in its safe operation.
4. All hydraulic retrieval equipment must be inspected and pressure tested prior to use as per
Roxar HRT Maintenance Procedure [section 4].
5. DO NOT EXCEED MAXIMUM PRESSURE RATING OF RETRIEVAL KIT WHEN
PERFORMING RETRIEVAL OPERATIONS.
6. Prior to performing any retrievals, notify the facility control room that process changes which
could vary system pressure such as surges caused by opening and closing of valves and
chokes must be delayed until completion of retrieval operations.
7. Prior to performing any retrievals ensure the pipeline pressure, temperature and media are
confirmed with facility operations personnel or control room.
8. Ensure the relevant Material Safety Data Sheets for the pipeline media are adhered to.
9. As a minimum the following PPE is required when performing hydraulic retrieval operations:
a. Hard Hat
b. Safety glasses
c. Long sleeved fire-retardant shirt & fire-retardant trousers or full -length fire retardant
coveralls
d. Hearing protection
e. Chemical resistant latex gloves or equivalent
f. Gloves suitable for mechanical operations e.g. Cheetah or Ironclad
g. Additional PPE may be required depending on facility requirements and / or MSDS
requirements
10. When bleeding the contents of the hydraulic retrieval tool ensure an appropriate container with
an earth strap is used to remove the risk of static discharge
No deviation from this
p
rocedure is
p
ermitted without
p
rior written authorization.

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1.4 Operator training
To ensure that any operator of Roxar Hydraulic Access System has the correct level of competency
and system understanding, Roxar Educational Services has dedicated training courses available.
1.5 Contact information
Roxar HQ, Norway
Gamle Forus vei 17
PO Box 112
4065 Stavan
g
er, Norwa
y
Tel: [phone]
Fax: [phone]
E-mail: info.roxar
@
emerson.com
Web: www.emerson.com
Go to Roxar brand under Emerson Automation Solutions
1.6 Product support
To ensure the optimal response, regardless of time zones, and to minimise downtime of the product,
Roxar Global Service Centre is organised through a network of service centres world-wide.
Manned by skilled operators and engineers, our Global Service Centre supports all your service
requirements or technical queries. Our experienced staff will receive, direct and manage all interactions
through the Global Service Centre allowing maximum flexibility through all communication mediums.
For Product Support Help Desk please contact [e-mail]

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2. HRT SYSTEM COMPONENTS
The hydraulic retrieval tool is together with the service valve used to replace different devices (probes,
coupons, injection quills etc.) installed in traditional hydraulic access fittings during operation, meaning
that piping and vessels are pressurized.
It is strongly recommended that any work with the hydraulic retrieval tool is
conducted only by personnel that has undergone proper training and certification
The service valve can also be delivered as single isolation version, and the procedures for operation
and maintenance are similar as for the double isolation. Based on this the single isolation valve is not
further described in this document.
Figure 1: Hydraulic retriever and service valve
2.1 Hydraulic Retriever
The Double Acting Hydraulic Retriever is a tool designed for servicing all kinds of equipment that can
be installed into the 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 Double Acting Hydraulic Retriever works as a hydraulic cylinder with a piston rod moving in and
out.
The Double Acting Hydraulic Retriever is operated by either a manual (hand operated) hydraulic pump,
or an air-driven hydraulic pump.

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Figur 2: Hydraulic retriever main components

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2.2 Service Valve
The service valve is a double isolating type, meaning that it has two balls that can be closed
individually. The service valve also has by-pass valves for each of the balls and a separate bleed valve.
Figure 3: Double isolating service valve
The double isolation service valve consists of the following main components:
1. End section
2. Main body upper section
3. Main body, service valve
4. By- pass valves (2x)
5. Ball lever (2x)
6. Bleed valve
*Internals (isolation balls and seals) are not shown
2.3 Hydraulic Access Fitting
The Hydraulic Access Fitting has either a welded or flanged connection to the pipe and holds the plug
and/or any type of monitoring device. A heavy-duty cover holds the plug in position during normal
operation. A system of 4 locking pins holds the plug in position when cover is removed for retrieval
operations.

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Figure 4: Hydraulic access fitting assembly
2.4 Air / Hand pump
When monitoring equipment is to be installed in an access fitting, 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.
There are two types of hydraulic pumps:
 Air driven pump (dual port)
 Manual pump (dual port)
Figure 5: Hydraulic pump devices
2.5 Tools list
The table below lists all the tools needed for operation and maintenance of the hydraulic retrieval tool.

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Description Size Quantity
(
pc
)
Comments/ Applicable for
Spanner 26, 30, 32mm 1 Hydraulic sold/hollow plug.
Adjustable spanner Small & Medium 2 Misc
Unbraco/Allen key kit 2.5-10 mm kit Misc
Unbraco/Allen key bits 6-10 mm Kit Misc
Ratchet ½” inch 1
Torque wrench 25-200Nm 1 Misc
Torque wrench 100-500 Nm 1 Misc
Hex socket 10 mm, 3/4in drive 1 Misc
Hex socket 17 mm, 3/4in drive 1 Misc
Hex socket 5 mm, screw key 1 Misc
Brass/Plastic hammer 1 Hammer nuts
Retainer ring pliers 1 Misc
Wrench >105 mm 1 Hydraulic access fitting cover
Multipurpose lubrication NA WD40, CRC 565 or similar
O-Ring grease NA
Grease/lubricant Chesterton 785 or similar
Table 2: Tools list

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3. OPERATION
Any variant of the intrusive monitoring equipment mounted onto the plug (ER probe, LPR probe or
Coupon Holder or injection quill) is in this procedure referred to as 'a device'. The following procedure
will describe how such a device is removed and installed in a pressurized vessel using the hydraulic
retrieval tool.
It is important to understand that this manual is not a single source of information, and that any
environment or specific application needs to be evaluated before any process is initiated. It is
recommended that a Safe Job Analysis is performed before any work is commenced.
It's strongly recommended that 2 properly trained and skilled retriever operators
are conducting the live operation on pressurized piping
3.1 Personnel qualifications
For a retrieval operation, it's strongly recommended that 2 (two) skilled and trained operators are
performing the retrieval task. At least one of operators needs to be certified for the task with a long and
solid track record. The other person needs as a minimum to have attended, and passed, a theoretical
and practical training course for retrieval operators. For further questions to this, contact your local
Roxar and Emerson representative.
3.2 HSE
1. Roxar Online Hydraulic Retrieval Operations Risk Assessment must be used and followed in
conjunction with this document when performing all online hydraulic retrieval operations.
2. Two Roxar trained operators are required to perform online hydraulic retrieval operations at all
times. At least one of operators needs to be certified for the task with a long and solid track
record. The other person needs as a minimum to have attended, and passed, a theoretical and
practical training course for retrieval operators.
3. Do not attempt to use any hydraulic retrieval equipment unless you have been properly trained
and deemed competent in its safe operation.
4. All hydraulic retrieval equipment must be inspected and pressure tested prior to use as per
Roxar HRT Maintenance Procedure [4].
5. DO NOT EXCEED MAXIMUM PRESSURE RATING OF RETRIEVAL KIT WHEN
PERFORMING RETRIEVAL OPERATIONS.
6. Prior to performing any retrievals, notify the facility control room that process changes which
could vary system pressure such as surges caused by opening and closing of valves and
chokes must be delayed until completion of retrieval operations.
7. Prior to performing any retrievals ensure the pipeline pressure, temperature and media are
confirmed with facility operations personnel or control room.
No deviation from this
p
rocedure is
p
ermitted without
p
rior written authorization.

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8. Ensure the relevant Material Safety Data Sheets for the pipeline media are adhered to.
9. As a minimum the following PPE is required when performing hydraulic retrieval operations:
h. Hard Hat
i. Safety glasses
j. Long sleeved fire-retardant shirt & fire-retardant trousers or full -length fire retardant
coveralls
k. Hearing protection
l. Chemical resistant latex gloves or equivalent
m. Gloves suitable for mechanical operations e.g. Cheetah or Ironclad
n. Additional PPE may be required depending on facility requirements and / or MSDS
requirements
10. When bleeding the contents of the hydraulic retrieval tool ensure an appropriate container with
an earth strap is used to remove the risk of static discharge.
3.3 Preparations (pre job)
Before any retrieval operations are initiated, key points need to be checked and verified. From a strictly
general point of view these are typically including, but not limited to:
1. Use of the Hydraulic Retriever Tool involves bleeding off pressurized fluid/gas from the pipe
system. If the pipe system contains hydrocarbons, bleeding off liquid/gas might trigger gas
detectors, hence such operations must always be clarified with the operators before the job
starts.
2. Have Job Safety & Environment Analysis filled out and Work Permit Active before starting any
work.
3. Control room / facility operators are to be notified when work starts or stops at each location to
ensure any gas detectors can be bypassed and hot work nearby can be stopped.
4. Verify size of Retrieval tool is sufficient for the actual device length to be retrieved at each
location.
5. Make sure to have appropriate container with earth strap, absorbent matting, and rags available
to capture any liquids that may come out during the bleed-off of the retrieval tool.
6. Inspect all parts of the retrieval tool and service valve and pump before using.
See Roxar HRT Maintenance Procedure [section 4].
It's important that all safety precautions are taken, and a safe job analysis is
performed before any installation work is started
Never place yourself in direct line when working on potential pressurized components,
like locking pins, probe adapters, plug nuts.

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Ensure that actual pipe pressure is confirmed before any operation is started
A bleed off sequence might contain hot fluid or poisonous gas
3.4 Access fitting Inspection & Preparation
1. Check pipeline pressure and pipeline contents with an
operator before operation begins.
2. Check Hydraulic Access Fitting. This includes:
2.1. If pressure proof cover: Check gauge. If pressurized, open
cover bleed valve, release pressure and close. If no pressure
build-up, continue the operation. If pressure builds, stop the
operation.
2.2. Check that the cover is sufficiently tightened.
2.3. Screw out locking pins for inspection, one at a time.
2.4. Check the locking pin O-rings for cuts and wear and replace
if necessary. If a locking pin’s O-rings are replaced,
change all O-rings on the remaining locking pins with this
fitting.
2.5. Inspect the locking pin hole and clean if necessary, especially the sealing
surface where O-rings seat.
2.6. Use anti-seize lubricant for the locking pin threads and the O-rings.
2.7. Put locking pin back in hole and tighten down. Go to next locking pin on this fitting and perform
the same steps as above until all locking pins have been inspected.
3. Ensure all locking pins are sufficiently tightened after inspection.
It is important to check only one locking pin at a time. Remaining locking pins shall be in
position when checking one locking pin
Figure 1: Step 2

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3.5 Online Retrieval of Device
4. Remove plug nut, or if a continuous monitoring cable is connected, remove the cable assembly from
the fitting.
5. Remove the heavy duty protective cover. Check for leaks around the plug, and around the locking
pins.
If leaks are discovered, then put the cover back on and go
through the steps above again for checking the hydraulic access
fitting.
If the leaks cannot be stopped, then put the cover back on and
tighten it. Do not continue with this location. It will have to be
more thoroughly investigated when the line can be shut down.
6. Check the external threads on the access fitting. Clean and
lubricate if necessary.
7. Clean and check the sealing surface on top of the access fitting
where the O-ring from the service valve will seat.
If any damage or pitting is noticed, do not continue with this
location. Access fitting is damaged and will have to be changed
out when the line is shut down.
8. Inspect the O-ring in the bottom end of the service valve. Make
sure O-ring is installed. (If missing; install new O-ring)
9. Mount the service valve on the access fitting. Tighten it to the fitting using a
plastic – or brass – spark proof hammer.
10. Connect the hoses from the pump to the retrieval tool. Connect the hose that is connected to the
“install” port of the pump to the top quick connector of the retrieval tool (closest to the head valve).
Connect the hose that is connected to the “retrieve” port of the pump to the middle quick connector
of the retrieval tool. Tighten the safety nut on all quick couplings.
11. Make sure the head valve is open (1 turn out from full is sufficient).
Figure 2: Steps 5 - 9
Remember to close the safety nut on the quick couplings

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12. Set the pump to “install” and pump until the connecting rod is fully extended. Continue to pump until
the pressure inside the retriever is a minimum of 50 bars and close the head valve watching the
pressure gauge on the pump.
13. Check that the washer at the end of the connecting rod is in place.
14. Pull back the hammer nut and inspect the O-ring at the end of the retriever. Make sure o- ring is
installed. If this is missing; install new O-ring
15. With the head valve closed, release pressure from the pump, untighten the quick coupling safety
nuts and disconnect the hoses.
16. Hold the retrieval tool so the connecting rod faces the service valve. Put the connecting rod through
the service valve, and mate the threads on the rod and the plug. Screw the rod into the plug by
rotating the retriever. Screw until the rotation stops. Do not tighten.
17. Connect the hoses from the pump, tighten safety nuts, and set the pump to “retrieve”. Open the
head valve. Hold the retrieval tool hammer nut away from the service valve threads. Pump in
“retrieve” mode until the retrieval tool is pulled towards the service valve. Pump to approx. 20-50 bar
and visually ensure that the two surfaces retriever / valve mate correctly.
18. Connect the hammer nut to the service valve, and screw until it stops. Then tighten the hammer nut
by use of the plastic or brass spark proof hammer.
19. Set pump to “Install” and pump until the pressure in the retriever is at least 100 bars higher than the
pressure inside the pipeline (confirm line pressure with the control room). If it is difficult to determine
the exact pipeline pressure, the pressure on the pump should be increased to an even higher level.

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20. Loosen all of the locking pins in the access fitting. The locking pins should only be screwed out until
the head of the pin is flush with the outside of the access fitting. The locking pins should be easy to
loosen. If the locking pins are difficult to loosen (high friction), the pump pressure might be too low.
Tighten the locking pins and then increase the pressure. Loosen locking pins again.
Figure 3: Steps 20 - 22
21. Check to ensure that the service valve handles are fully open. Also check that the bleed-off valve on
the retrieval tool is closed and that both by-pass valves are closed on the service valve.
22. Close head valve to keep the pressure within the retriever.
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 must be visible. If the pins are unscrewed too far, they will
leak when the plug is retrieved.

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23. Switch pump from “install” to “retrieve”.
24. Slowly open the head valve to release the pressure. The connecting rod will start moving up into the
tool (the line pressure will push it back), close the head valve and check for leaks (this is done to
shorten the period / distance to pump the plug back in case of leaks). Reopen the head valve. Use
the pump in retrieve mode and start pumping until the pressure gauge on the pump shows that
pressure is starting to build up inside the retriever. This indicates that the probe is fully retrieved.
Check for leaks around the locking pins. If leaks do occur, the probe must be reinstalled.
Figure 4: Step 24
25. 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).
26. Close the service valve. If the valve cannot be closed, the probe must be installed again, and the
valve inspected in order to determine the reason for this problem.
If the ball valve still cannot be closed, it is most likely due to one of the following causes:
26.1. There are large amounts of sand/debris inside the valve, hampering the rotation of the ball.
26.2. The device is not fully retrieved.
26.3. The device is fully retrieved, but the device length exceeds the capacity of the retriever.
27. If a double service valve is being used, close the lower service valve ball first. Make sure that both
bypass valves on the service valve are closed. 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.
When using the pump in "retrieve" position, the pressure should never exceed 100 bars
(see gauge on pump). This 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 100 bars, it should be
left inside the fitting until the next shut down.

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28. The pressure inside the retrieval tool must be released (contact control room and inhibit gas
detectors in the area). Use the bleed-off valve on the retrieval tool. Have a bucket ready to catch the
liquid that will come out. Put absorbent pads down as added protection against spillage. A hose can
be connected to the bleed off valve if needed to direct the flow. The bleed-off valve should be open
as long as there is liquid or gas coming out from the retrieval tool. This is to get as much liquid as
possible out of the retriever tool before it is disconnected from the service valve.
With the pressure in the retrieval tool reduced to 0, it must be checked that the service valve is
sealing properly. This is 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 retrieval tool. 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 device must be reinstalled, and the valve must be
serviced. If a double service valve is being used close the upper service valve ball.
Figure 5: Steps 25 – 28
29. If the service valve is sealing properly, the retriever can be removed from the service valve. Loosen
the hammer nut, and unscrew it from the valve. This should be able to be done without any
resistance between the valve and tool. Then lift the retrieval tool away from the service valve. Be
aware of liquid that might flow out as the retriever is disconnected from the service valve. If the
access fitting is in the 6 o’clock position, the retriever might be filled with liquid, and therefore, after
being disconnected it must be held in the same position until it can be emptied into a bucket.
Figure 6: Steps 29 & 30
30. Place the retrieval tool with the hammer nut end up, and set the pump to “install”. Pump the
plug/probe assembly out of the retrieval tool. The probe/probe assembly can now be inspected,
It is imperative to make sure that it is only the retrieval tool that is loosened from the
service valve, and that the service valve is still kept properly tightened onto the access
fitting.
Furthermore one must be careful when loosening hammer nut on retriever. The tool is no
longer attached to the plug and will fall down or tip over if not handled properly.

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serviced or replaced. Make sure primary packing is replaced and correct version of wear rings are
installed. Change out wear rings if damaged.
Make sure the wear rings are of the new type with a minimum 5mm (1/4”) gap to avoid the
possibility of pressure building up. The old type wear rings with no gap, is never to be used (or
re-used
)
.

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3.6 Online Installation of Device
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.
31. Replace the plug/probe assembly onto the connecting rod of the retrieval tool.
Set pump to “retrieve”, and pump until the end of the plug/probe has been
retracted 10-15cm into the retriever. Do not fully retract the rod to the bottom
of the retriever.
32. Check that the O-ring in front of the tool is in place, then lift the retriever onto
the service valve, screw the hammer nut onto to the valve and tighten it.
33. Set pump to “install”. Make sure that the bleed valve on the tool is closed.
34. If a double service valve is being used, open the by-pass valve for the upper
ball (closest to the retrieval tool), and then open the ball itself.
35. Open the by-pass valve for the lower ball (closest to the access fitting) and
then open the ball itself. The pressure in the retriever will now increase to line
pressure.
36. If the pressure 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 50 bars). The pressure should then be balanced by
use of the pump.
To balance the pressures with the pump, use the following steps:
a. Set the pump to “Retrieve” and pump until the probe is fully retrieved
b. Install the back pressure quick coupling assembly on the bleed off valve. Figure 7: Steps 31 - 36
Remember to close the safety nut on the quick couplings
Ensure that both balls are full
y
o
p
ened.