High Pressure Access Systems - Alabama Specialty Products, Inc.
Contents
1. Metal Samples Corrosion Monitoring Systems 2 High Pressure Access Systems Operation Manual Metal Samples Corrosion Monitoring Systems A Division of Alabama Specialty Products Inc 152 Metal Samples Rd Munford AL 36268 Phone 256 358 4202 Fax 256 358 4515 E mail msc alspi com Internet www metalsamples com Houston Office 6327 Teal Mist Lane Fulshear TX 77441 Phone 832 451 6825 Table of Contents SVS UCU COM iur e M 1 Safet Precaution S uite chia iecit cedes aded eodd adeo edes tu Dedi dives aln eite i eaa d 2 ACCESS FILLING BOOV TYDES oes t ete setate EE o SRUEP D lcm tO dT UD npe REX ind 3 pee Type amp Nonsree TV DES vonise O 5 Attaching the Access FIEEDB BOOY soa d setis rt pene autore EREO XE OX Eo Dine pb ura oYu OESE ED aan 8 IU ASS ONAN c TI UU mi 10 SOIC MUS Ss seouetitim mand ut Eno I md qu IEEE MEE 11 POM OMY brc 12 STAINING e Orientine the PIUIB sn eed xn da EE 13 uiou udi R8e le rc 14 Cover Installation amp Removal ccscscscscscsccccscecscscscscscecscscscscscscscecesescsesesesesesescsescscscceces 16 High Pressure Access Systems System Overview High Pressure Access Systems are specialized piping arrangements which permit internal access to production plant vessels and pipework operating under full process conditions The corrosion monitoring industry standard for such access systems is based on a 2 inch n2. 15 HA700734413 HA700732413 HA700436709 HA700435709 HA700735413 HA700731413 HA700480413 HA700481413 HA700482413 HA700483413 HA700484413 Carbon Steel Carbon Steel CS cover 316 SS bleed val CS cover 316 SS bleed val amp gauge CS cover 316 SS bleed val amp gauge CS cover 316 SS bleed val CS cover 316 SS gauge 2 5 Ibs 1 6 kg 2 0 Ibs 0 9 kg 0 5 Ibs 0 2 kg 0 5 Ibs 0 2 kg 9 bs 4 1 kg 9 bs 4 1 kg 9 bs 4 1 kg 10 Ibs 4 5 kg 9 bs 4 1 kg 9 Ibs 4 1 kg 9 bs 4 1 kg Cover Installation amp Removal All pressure retaining covers are supplied with an internal o ring Ensure that the o ring is installed into the internal groove Ensure the external threads on the access fitting body are clean and dry Lubricate the threads with an appropriate grease and thread the cover onto the fitting Non pressure retaining covers can be installed hand tight Pressure retaining covers should be tightened with a spanner wrench To remove the cover unscrew the cover from the fitting using a spanner wrench to loosen the cover if required If pressure retaining covers are used be sure all pressure is bled from the cover before removal If it is not possible to bleed pressure the cover should not be removed until the line is depressurized 16
3. and dampened on the outside only 4 Place the access fitting on the line and align 5 Establish proper weld gap by placing 1 16 spacer rods under the access fitting 6 Most steels should be preheated prior to welding when the fluid or metal temperature is less than 50 F 7 Arc welding should be used to minimize warping 8 Preheat access fitting body to 400 F and tack weld using AWS 1 8 welding rod of the proper grade 9 Remove weld gap spacers Remove tack weld slag 10 Tie the root pass into the tack weld to make complete fusion Apply a stringer bead around the base of the fitting removing slag at each pass 11 Tempil sticks should be used to insure that the access fitting body temperature does not exceed 1000 F 12 Apply continuous cover beads to fill the bevel 13 Apply a post heat of 600 F for fifteen 15 minutes Wrap with insulating cloth and allow to cool 14 Hot tapping will be necessary for lines in service Note Weld time approximately one 1 hour with welder and helper The procedure described above is for general access fitting installation reference Metal Samples Corrosion Monitoring Systems shall not be held responsible or liable in any way for loss or damage resulting therefrom or any regulations which they may conflict Plug Assemblies The Plug Assembly is the retrievable carrier which holds corrosion monitoring chemical injection or various other devices which may be installed through the acc
4. arrangement Fittings with 1 4 1 2 3 4 or 1 FNPT side tee ports are available as standard items Tee type access fitting bodies are used with Chemical Injection Systems Sampling and Sand Monitoring Systems If required the side tee port may be sealed off with a pipe plug This would allow devices normally used with the non tee type access fittings to be used with the tee type access fittings NOTE The installation and removal of the pipe plug requires the process stream to be shut down and depressurized The materials of construction of tee type access fitting bodies are the same as the non tee type access fitting bodies Protective Cover Solid Plug Tee Type Nipple Access Fitting Body To Feed Pump Injection Nut mak P or Sampling Cylinder Shutoff Valve Injection System using a Tee Type Access Fitting Body Non Tee Types Model HP 1000 Model HP2000 Model HP3000 Model HP4000 Flareweld Buttweld Socketweld NPT Height in Model HP5000 Model HP6000 Model HP7000 ANSI Flange RJ ANSI Flange RF API Flange Flange Size Height in 1508 4 6008 9715008 Temperature Rating 20 F 28 9 C to 350 F 176 6 C Pressure Rating 6000 PSI or as Flange Size Tee Types Model HP1100 Model HP2100 Model HP3100 Model HP4100 Flareweld Buttweld Socketweld NPT in lbs in lbs n lbs in lbs S Model HP5100 Model HP6100 Model HP7100 ANSI Flange RJ ANSI Flange RF
5. the manual and if possible perform a trial operation on a mock fitting 4 In addition to the requirements of this manual all plant safety requirements and environmental regulations must be followed Access Fitting Body Access Fitting Body Types High Pressure Access Fitting Bodies are available in styles that may be welded Flareweld Socketweld and Buttweld threaded NPT or flanged API ANSI RF ANSI RJ to the pipe or vessel wall Flareweld Buttweld Socketweld NPT Flanged 1 Flareweld HP1000 HP1100 Flareweld bodies are the most widely used These bodies incorporate a reinforced welding neck and also have a radius machined into the base to accommodate the curvature of the pipe or vessel to which the body is welded 2 Buttweld HP2000 HP2100 Buttweld access fittings are designed to be buttwelded directly to a 2 pipe end 3 Socketweld HP3000 HP3100 Socketweld fittings are designed to be welded directly to a 2 socket end 4 NPT HP4000 HP4100 NPT fittings can be threaded into a 2 female NPT fitting 5 Flanged Flanged fittings are available in three standard configurations a ANSI Ring Joint RJ HP5000 HP5100 b ANSI Raised Face RF HP6000 HP6100 c API HP7000 HP7100 Access fittings are manufactured from materials which conform to NACE MR 0175 specifications for sour service Choice of material for the access fitting body is based on minimum operating temperature as well as process stre
6. API Flange Height Weight Height Weight Height Weight Height Weight in lbs in lbs in lbs in 9 50 7 25 7 25 11 50 7 25 7 25 4 6004 12 75 l 7 25 7 25 9 1500 25 75 i 8 25 8 25 2500 40 20 8 25 8 25 ANSI 4 6004 Flange RF 9 1500 2500 20005 18 000 7 25 3 5000 38 00 8 25 10000 45 50 8 25 Temperature Rating 20 F 28 9 C to 350 F 176 6 C Pressure Rating 6000 PSI or as Flange Size 7 Attaching the Access Fitting Body Access Fitting Bodies which have a welded end connection flareweld buttweld or socketweld must be welded according to local and plant codes NPT type access fittings are manufactured in accordance with ANSI ASME B1 20 1 Specification for Taper Pipe Threads This fitting should be installed by a qualified technician using standard protocol for taper pipe threads ANSI flange fittings are manufactured in accordance with ANSI B16 5 Specification for Flanges and Flanged Fittings Flange gaskets and stud and nut sets are not provided with the access fitting body This fitting should be installed by a qualified technician using standard protocol for flange installation General Welding Instructions 1 Determine if the system in which the access fitting is to be placed will permit welding 2 Remove the plug assembly from access fitting prior to welding 3 Protect the internal and external threads from weld splatter with a temperature resistant cloth wrapped around the body
7. am corrosivity Standard temperature materials are suitable for use above a minimum operating temperature of 20 F 29 C Low Temperature materials should be selected for minimum operating temperatures below this value The Metal Samples Corrosion Monitoring Systems standard material specification for Flareweld Socketweld Buttweld and NPT bodies is AISI 1018 for standard temperature and ASTM A350LF2 for low temperature For flanged fittings ASTM A105 is used for standard temperature and ASTM A350LF2 for low temperature However all access fitting components can be made to order in any customer specified material carbon or stainless steel duplex materials or other more exotic alloys All access fitting bodies have an external 3 inch ACME thread which is used to attach the service valve during retrieval operations Access fitting bodies should always be fitted with a cover which is designed to protect both external thread and also the service valve sealing surfaces Tee Type amp Non Tee Types Access Fitting Bodies are available as either non tee types or tee types Non tee access fitting bodies are used in applications such as coupon holders and monitoring probes Tee type access fitting bodies are used in applications where inlet or outlet access to the process stream is required A side tee port is drilled and tapped in the access fitting s extra thick body to provide an integral connection point for a nipple and shut off valve
8. ess fitting There are two distinct types of plug assemblies the Solid Plug and the Hollow Plug The plug assembly screws into the bore of the access fitting body and is designed to seal the fitting against line pressure When tee type access fittings are being used a pipe plug or nipple and shut off valve is additionally required to seal the fitting The standard material of construction for the plug assembly is 316 Stainless Steel It should be noted that when stainless steel or duplex materials are specified for the access fitting body the plug assembly should be specified to be Nitronic 60 to prevent thread galling All plug assemblies are individually pressure tested at the factory and are rated for operation at 3600 psi The operating temperature range for standard plug assemblies is 50 F 45 C to 350 F 176 C but this range can be extended by use of alternative sealing materials 10 Solid Plugs Solid plugs carry coupon holders injection sampling systems sand probes and bioprobes The solid plug nut is unscrewed from the base of the plug and replaced by the device being installed A left hand thread is used to ensure that installed devices do not become loose during the retrieval procedure Pipe Plug Protects internal threads and provides secondary backup seal Must be removed during retrieval operations Hi Ul Solid Plug Body Il O Ring Seal Primary Packing Seal Solid Plug Nut On
9. essure rating of 4000 psi and are available with an optional bleed valve and or pressure gauge Covers are available with or without a center hole Center holes are required when an external sensor connection is required to be permanently installed Covers with an unthreaded 1 3 8 3 5 cm diameter center hole are required for installations where mechanical Hydrogen Probes are installed Covers with a 1 2 NPT center hole are required where continuous monitoring of electrical probes is required Connection of an electrical probe to a permanent monitoring instrument requires the use of a probe adapter that extends through the 1 2 hole in the cover The probe adaptor must be ordered separately Pressure 4 Gauge lS 1 4 NPT Plug wv VW dq Cover 1 4 Bleed Plug Q7 ACME Thd we ee st Pressure O ring eee Gauge Needle Valve 1 4 NPT Plug O ring Heavy duty pressure rated cover with NPT center hole and with 2 ea 4 NPT holes for needle valve and pressure gauge Heavy duty pressure rated cover without center hole and with 2 ea NPT holes for needle valve and pressure gauge Non Pressure Rated Covers More economical than heavy duty pressure rated covers non pressure rated covers are internally threaded to protect against mechanical damage to the PIL 7777777 LLLI external access fitting threads Non pressure rated covers are available in 77 A ZZZ plastic or metal w
10. ith the plastic version having the added advantage of being lightweight and non sparking They can be ordered with or without a center hole 14 Protective Covers Part Numbers Non Pressure Rated Cover without Hole Non Pressure Rated Cover w 1 2 NPT Hole Non Pressure Rated Cover without Hole Non Pressure Rated Cover w 1 2 NPT Hole Heavy Duty Pressure Rated Cover w o Hole Heavy Duty Pressure Rated Cover with 1 2 NPT Hole Heavy Duty Pressure Rated Cover and Bleed Valve Heavy Duty Pressure Rated Cover Bleed Valve amp Pressure Gauge Heavy Duty Pressure Rated Cover Bleed Valve Pressure Gauge and 1 2 NPT Hole Heavy Duty Pressure Rated Cover w Bleed Valve amp 1 2 NPT Hole Heavy Duty Pressure Rated Cover w Pressure Gauge amp 1 2 NPT Hole Intermittent Monitoring Chemical Injection Continuous Monitoring Intermittent Monitoring Continuous Monitoring Intermittent Monitoring rated for 6 000 PSI Continuous Monitoring provides a secondary seal and allows for probe adapter rated for 6 000 PSI Continuous Monitoring provides a secondary seal rated for 6 000 PSI Continuous Monitoring provides a secondary seal rated for 6 000 PSI Continuous Monitoring provides a secondary seal rated for 6 000 PSI Continuous Monitoring provides a secondary seal rated for 6 000 PSI Continuous Monitoring provides a secondary seal rated for 6 000 PSI
11. ly used when no other device is attached Description PatNs Material Pipe Plug HA700697158 316SS Solid Plug Body HA700006158 316 SS O Ring HA700600834 Primary Packing HA700266785 PTFE 2596 G Solid Plug Nut HA7002101 58 316 SS 09158E1032ST0187 316SS Hollow Plugs Hollow plugs are used with electrical resistance probes linear polarization resistance probes and hydrogen probes To connect these devices the hollow plug seal nut is removed and the monitoring device is screwed into the female thread in the base of the hollow plug A left hand thread is used Access is allowed through the top of the hollow plug for electrical connections to be made directly to probes for the purpose of taking readings Thread Protector Must be removed during retrieval operations T ILLU Hollow Plug Body Primary Packing Seal Hollow Plug Nut Eu Device Seal Bore Seal Nut Only used when no other device is attached Descip on Pao Mates HA700167 Probe Packing HA700277785 PTFE 25 G Hollow Plug Bore Sealing Nut HA700311158 316 SS Installing amp Orienting the Plug If the corrosion moni
12. ominal bore design When operated with a Retrieval Tool and Service Valve high pressure access systems allow the installation and retrieval of corrosion monitoring coupon holders probes chemical injection equipment and other devices to be carried out safely and without plant shutdown at working pressures up to 3 600 psi High pressure access systems are used most frequently although not exclusively in oil and gas production operations This is typical of high pressure operations in which users are not prepared to shut down and depressurize process systems in order to remove or install corrosion monitoring devices The Access Fitting Assembly consists of three main components 1 Protective Cover designed to protect the external threads of the access fitting body 2 Plug the carrier for the installed device Depending on the type of device being used a solid plug or a hollow plug is selected The plug assembly screws into the access fitting body and seal the bore of the fitting to contain line pressure 3 Access Fitting Body the specialized pipe fitting which is permanently attached to the process plant vessel or pipework Safety Precautions 1 Good engineering and operational practices should be adhered to at all times 2 Do not use the retrieval tool unless you have familiarized yourself with its operation 3 If this is the first time you have used the equipment or you are an infrequent user you should review
13. toring device requires radial orientation with the product flow coupon holder LP probe injection quill etc you will need to reference or index the plug assembly by filing a notch across the top of the hex see left The notch should be filed so that the device can be aligned with the product flow Apply an appropriate grease to the full length of the plug If inserting the plug under pressure use the Retriever Tool and Service Valve If inserting the plug manually thread the plug assembly into the access fitting body Do not use excessive force and be sure that the threads engage properly to prevent cross threading The reference mark as previously mentioned must now be aligned to product flow direction Turn the plug assembly hex clockwise until the mark aligns to the flow direction Make sure the fitting is clean and dry and install the thread protecting pipe plug into the top of the plug 13 Protective Covers Protective covers are designed with internal threads which mate with the access fitting body and are recommended to prevent damage to the fitting s exterior thread In addition they protect the surfaces against which the service valve seals during retrieval operations Heavy Duty Pressure Rated Covers Heavy duty pressure rated covers are manufactured as standard in AISI 1018 and are supplied with a paint coat finish suitable for the most aggressive environments Covers are individually pressure tested for a pr
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