Emerson Roxar User manual

User Manual
ROX000295904, Rev AC
June 2020
Roxar™ Mechanical Retrieval Tool User
Manual

2

Contents
Chapter 1 Introduction.............................................................................................................. 5
1.1 How to use this manual................................................................................................................5
1.2 Conformity to standards..............................................................................................................6
1.3 Abbreviations and terms..............................................................................................................6
1.4 Hazard messages.........................................................................................................................6
1.5 Personnel qualifications and safety.............................................................................................. 7
1.6 Warranty restrictions................................................................................................................... 8
1.7 Additional documentation and resources.................................................................................... 8
1.8 Assistance....................................................................................................................................8
Chapter 2 Technical description................................................................................................. 9
2.1 General information.................................................................................................................... 9
2.2 Mechanical retriever tool........................................................................................................... 10
2.3 Service valve.............................................................................................................................. 15
2.4 Hand pressure pump................................................................................................................. 19
Chapter 3 Preparation..............................................................................................................21
3.1 Initial preparation...................................................................................................................... 21
3.2 Tools and equipment.................................................................................................................22
3.3 Consumables for operation........................................................................................................22
Chapter 4 Operating instructions............................................................................................. 25
4.1 Retrieving a device.....................................................................................................................25
4.2 Installing a device...................................................................................................................... 29
4.3 Troubleshooting guidelines....................................................................................................... 31
4.4 Qualification requirements and training programs for operators............................................... 32
Chapter 5 Maintenance............................................................................................................35
5.1 Maintenance instruction............................................................................................................35
Appendix A Spare parts list......................................................................................................... 41
Appendix B Attachments............................................................................................................ 43
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Contents User Manual
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1 Introduction
The Roxar Mechanical Retrieval Tool kit consists of the following components:
•Roxar Mechanical Retrieval Tool
•Service valve
•Hand pressure pump
•Accessories
•Transportation case
This user manual describes how the retrieval operation is performed on pressurized
systems.
1.1 How to use this manual
This user manual describes the work performed generally. It does not specify all
applications that might be required in all cases. The system operator must evaluate the
installation and process needs of their system. If there is any need for further clarifications,
contact customer service.
For details on mechanical access fittings, covers and plugs, refer to the Roxar Mechanical
Access System User Manual which should be consulted for a more detailed understanding of
the access system main components.
This guide consists of the following sections:
1. Introduction provides a description of the user manual for the above-mentioned
products, which describes how the manual is structured and how it should be used.
This section also contains safety and contact information for the user.
2. Technical description provides more specific descriptions of the different product
components. This section explains the different measuring techniques, together
with recommendations for use of the different types of equipment. It discusses the
weight, outline dimensions, restrictions, and information about how to order
products.
3. Preparation describes all necessary preparations for installing this equipment,
including tools and equipment and the list of consumables.
4. Operating instructions contains checklists, precautions, consequences, hazards,
observations, operator qualifications, and system reporting during operational
conditions.
5. Maintenance describes all necessary precautions and maintenance operations, in
order to ensure safe and reliable operation. This section contains detailed
procedures for routine inspection, periodic maintenance, corrections, and minor
repair with recommended spare parts, consumables, reporting requirements,
relevant document references, and the skill requirements for a minimum crew.
6. Spare parts list gives all necessary spare parts for the different equipment during
operation.
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7. Attachments contains assembly drawings referenced in the manual.
1.2 Conformity to standards
This document has been issued in compliance with the most common international
standards for user manual documentation.
1.3 Abbreviations and terms
Term Definition
Device Any variant of the inline monitoring equipment mounted onto the plug. In
this document, the ER probe, LPR probe, coupon holder, injection quill,
sand probe, or sacrificial probe are all referred to as devices.
GSC Global Support Center
MSDS Material Safety Data Sheet
PEEK Poly Ether Ether Ketone
PPE Personal Protective Equipment
PTFE Poly Tetra Fluoro Ethylene
1.4 Hazard messages
This document uses the following criteria for hazard messages based on ANSI standards
Z535.6-2011 (R2017).
DANGER
Serious injury or death will occur if a hazardous situation is not avoided.
WARNING
Serious injury or death could occur if a hazardous situation is not avoided.
CAUTION
Minor or moderate injury will or could occur if a hazardous situation is not avoided.
NOTICE
Data loss, property damage, hardware damage, or software damage can occur if a
situation is not avoided. There is no credible risk of physical injury.
Physical access
NOTICE
Unauthorized personnel can potentially cause significant damage and/or misconfiguration
of end users' equipment. Protect against all intentional or unintentional unauthorized use.
Physical security is an important part of any security program and fundamental to
protecting your system. Restrict physical access to protect users' assets. This is true for all
systems used within the facility.
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1.5 Personnel qualifications and safety
Read and follow all instructions, dangers, warnings, and cautions to avoid personal injury
or property damage during system operation. Emerson is not responsible for damage or
injury resulting from unsafe use of products, lack of maintenance, incorrect installation of
equipment or system operation. If in doubt about any applications and safety precautions
described in this document, contact Emerson.
Only personnel with necessary training and certification should operate the mechanical
retrieval tool on pressurized lines. Emerson recommends two skilled and trained operators
to perform the retrieval task. At least one of the operators must be certified for the task
and experienced. At a minimum, the other operator needs to have attended and passed a
theoretical and practical training course for retrieval operators. For further questions
about training requirements, contact your local Emerson representative.
Operations risk assessment must be used and followed in conjunction with this document
when performing all online retrieval operations.
Ensure that all end user and installation specific safety requirements are read, understood
and adhered to.
Ensure that any operator that is conducting work on the equipment, is following end user
guidelines on the use of protective equipment including, but not limited to:
•Safety helmet or hard hat
•Steel-toed shoes
•Safety glasses
•Working gloves (suitable for mechanical operations)
•Chemical resistant latex gloves or the equivalent
•Long-sleeved, fire-retardant shirt and fire-retardant trousers or full-length fire
retardant coveralls
Additional PPE may be required depending on facility requirements and MSDS
requirements, if applicable. Failure to do so may result in personnel injury.
NOTICE
Do not attempt to use any retrieval equipment unless you have been properly trained and
deemed competent in its safe operation.
All retrieval equipment must be inspected, and pressure tested prior to use as described in
the operating instructions (refer to Operating instructions).
NOTICE
Observe all precautionary signs posted on the equipment to avoid serious injury.
WARNING
Risk to Personnel and Equipment: Operation of the Roxar Mechanical Retrieval Tool on
pressurized lines may potentially imply operational risk for personnel and equipment
from the potential escape of hot gas or liquid, which could result in serious injury.
Observe all precautionary signs on the equipment.
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WARNING
Risk to Equipment: The operation of the Roxar Mechanical Retrieval Tool kit involves
heavy equipment handling. Observe the following guidelines to avoid potentially serious
injury:
•Be aware of your limitations and ask for assistance if needed.
•Do not attempt to lift weight beyond your capacity.
•Lift with your legs, not your back.
Note
Mechanical lifting tools may also be used in some locations to reduce risk.
WARNING
Risk to Personnel and Equipment: If you exceed the maximum pressure rating of the
retrieval kit, corrosive gas or liquid can spill out and cause serious injury. When
performing retrieval operations, do not exceed the maximum pressure rating of the
retrieval kit.
NOTICE
Attending the mechanical retrieval tool training course is not considered sufficient for
operating the tool on pressurized lines. Emerson requires a two-man crew with formal
training. Additionally, at least one of the operators must have a record of extensive field
experience and be certified for this work.
Emerson assumes no responsibility for incidents, or consequences of incidents, occurring
as a result of the use of either mechanical or hydraulic retrieval tools by others than
Emerson or its designated personnel, and have no liability whatsoever for any such work.
Consult Emerson for more details on both training and certification.
1.6 Warranty restrictions
Visually inspect all components for shipping damage. If shipping damage is found, notify
the carrier at once. Shipping damage is not covered by the warranty. The carrier is
responsible for all repair and replacement costs resulting from shipment damage.
1.7 Additional documentation and resources
•Roxar Mechanical Access System User Manual
•Roxar Mechanical Retrieval Tool and Service Valve - Product Data Sheet
•Roxar Service Valve - Product Data Sheet
1.8 Assistance
The Roxar Global Service Center is organized through a network of service centers
worldwide, and supports all service requirements or technical queries. For the Product
Support Help Desk, go to: www.Emerson.com or contact your nearest Emerson service
provider.
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2 Technical description
This section gives a specific description of the Roxar Mechanical Retrieval Tool kit,
together with recommendations for the use of the equipment.
2.1 General information
The Roxar Mechanical Retrieval Tool is used to install and retrieve weight loss coupons,
corrosion probes, and both injection and sampling equipment. In addition, the tool can
also install and retrieve other devices that can be installed in Roxar mechanical 2-inch
access fittings, or mechanical 2-inch access fittings from other vendors that are
compatible or interchangeable with Roxar 2-inch mechanical fittings on pressurized lines.
Figure 2-1: Service engineer manning a Roxar Mechanical Retriever Tool and Service
Valve
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Figure 2-2: Roxar Mechanical Retrieval Tool (left) and Roxar Service Valve (right)
The service valve can also be delivered as a single isolation version. The procedures for
operation and maintenance are similar to those for the double isolation valve. For more
information about the single isolation valve, refer to the Roxar Service Valve - Product Data
Sheet.
2.2 Mechanical retriever tool
The Roxar Mechanical Retrieval Tool is based on a telescopic, pressure-balanced design.
This means that when a retrieval tool and service valve are installed on the access fitting,
the tool can be easily operated and telescoped freely, even if it is exposed to pipe pressure.
Figure 2-3: Roxar Mechanical Retrievable Tool
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Description
The mechanical retrieval tool is designed to allow pressure balancing through the hollow
or solid plug. When the plug is unfastened from its seat in the access fitting, pipe pressure
starts to flow into the retriever and gradually fills it until the pressure in the tool is identical
to the pipe pressure. Dimensions on the tool internals and sealing surfaces ensure that the
pressure is fully balanced. As a result, the tool moves freely under high pressure
conditions, while users can retrieve and install devices in the access fitting. The telescopic
operation refers to the expanding (out) and collapsing (in) the tool.
WARNING
Risk to Personnel and Equipment: If particles, dirt, or wax are present, the pressure
balance function described above may not provide satisfactory pressure balance in the
mechanical retrieval tool, and the pressure difference can force the mechanical tool to
expand uncontrolled, potentially causing harm to the operators. Therefore, apply
pressure above pipeline pressure to the tool by an external pump.
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Main components of the Roxar Mechanical Retrieval Tool
The mechanical retrievable tool consists of the following parts:
Figure 2-4: Mechanical retrievable tool components
A. Crane hook
B. Outer barrel
C. Inner rod or connecting rod
D. Inner barrel
E. Pressure gauge
F. Union thread adapter
G. Plug body
H. Plug pilot
I. Bleed valve
J. Hammer nut
Specifications and dimensions
The Roxar Mechanical Retrieval Tool can operate on pressurized lines and vessels up to
6,000 psi (420 bar) and fluid temperatures up to 400 °F (204 °C).
The main dimensions and weights are displayed in Figure 2-5 and both Table 2-1 and Table
2-2.
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Figure 2-5: Mechanical retrievable tool components
A. Clearance for mounting - 300 mm
B. Mechanical Retrieval Tool
C. Mechanical Retrieval Tool length, including the service valve
D. Service valve length - 230 mm
E. Mechanical access fitting
F. Front view
G. Side view
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Table 2-1: Mechanical retrieval tool with a single service valve: main dimensions and
weight
Maximum
Device Length
(mm)
150 240 350 425 640 920 1170
Mechanical
Retrieval Tool
length
extended,
including the
single valve (C)
[mm]
1160 1340 1565 1710 2140 2700 3200
Removal
clearance with
the single valve
(C+A) [mm]
1460 1640 1865 2010 2440 3000 3500
Mechanical
Retrieval Tool
weight [kg]
23.5 25.5 27.5 29.5 34 40 45.5
Retriever kit
approximate
weight [kg]
including the
single valve (13
kg)
65 67 69 71 75 81 87
Table 2-2: Mechanical retriever tool with a double service valve: main dimensions
and weight
Maximum
Device Length
(mm)
150 240 350 425 640 920 1170
Mechanical
Retrieval Tool
length
extended,
including the
double valve
(C) [mm]
1328 1508 1733 1878 2308 2868 3368
Removal
clearance with
the double
valve (C+A)
[mm]
1628 1808 2033 2178 2608 3168 3668
Mechanical
Retrieval Tool
weight [kg]
23.5 25.5 27.5 29.5 34 40 45.5
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Table 2-2: Mechanical retriever tool with a double service valve: main dimensions
and weight (continued)
Maximum
Device Length
(mm)
150 240 350 425 640 920 1170
Retriever kit
approximate
weight [kg]
including the
double valve
(22 kg)
74 76 78 80 84 90 96
2.3 Service valve
The Roxar Service Valve described in this user manual is a double isolating type containing
two balls that can be closed individually. It also contains by-pass valves for each of the balls
and a separate bleed valve.
The Roxar Service Valve is compatible with 2-inch access fitting systems provided by most
common corrosion monitoring.
Note
A single isolation service valve is also available (if required) to use with the Roxar
Mechanical Retrieval Tool. Procedures for operation and maintenance are the same for
both service valve versions. The use of single isolation service valve is not discussed further
in this document. For more information about the single isolation service valve, refer to
the Roxar Service Valve - Product Data Sheet.
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Service Valve components
Refer to the following figure to see the main components of the Roxar Double Block
Service Valve.
Figure 2-6: Double isolation service valve main components
A. Ball lever l
B. By-pass valve 1
C. By-pass valve 2
D. Main body service valve
E. End section
F. Main body upper section
G. Ball lever 2
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Specifications and dimensions
The Roxar Service Valve can operate on pressurized lines and vessels up to 6,000 psi (420
bar) and fluid temperatures up to 400 °F (204 °C).
The double block isolation version weights 22kg while the single isolation weights 13kg.
Figure 2-7: Dimensions for the double block and bleed valve
Note
In Figure 2-8, the probe length varies depending on the customer's pipe size and the flow
traveling through the pipe.
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Figure 2-8: Schematic of a double block and bleed valve with the Roxar Mechanical
Retrieval Tool
A. Clearance for mounting: 300 mm
B. Mechanical Retrieval Tool
C. Mechanical Retrieval Tool length, including the service valve
D. Service valve length: 230 mm
E. Mechanical access fitting
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2.4 Hand pressure pump
Hand pressure pumps are designed for manual operation and help to prevent a surge of
pressure during plug removal.
WARNING
If particles of dirt or wax are present, the operator can face difficulties trying to achieve
satisfactory pressure balance in the mechanical retrieval tool. The pressure difference
can force the mechanical tool to expand uncontrollably, potentially causing harm to the
operators. Apply pressure above pipeline pressure to the tool by an external pump.
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