cosasco model rsl retriever and service valve user manual
Contents
1. ATRIL 7 NSA u YUL gt ES e SN 555 O x EMT H 3843138 AUYNIN3Ud IdAOdddy 5530 512. 1 6 Clean all parts Examine all seals and o rings It is highly recommended that seals and o rings be replaced each time the service valve is disassembled and reassembled Even then prior to assembly they should be thoroughly inspected for nicks cuts or abrasions Lubricate the swivel on the hammer nut adapter assembly 13 Install the hammer nut seal adapter to access fitting body o ring 12 in the hammer nut to body retainer 15 Install the retainer to body o ring 16 in the enclosed end of the valve body 20 Install the seal adapter plate 15 and the hammer nut adapter assembly 13 to the valve body 20 using 5 8 Allen head cap screws 14 Use a 1 2 Allen wrench and torque to 90 ft Ib Install one of the two seat seal rings 18 and its carrier 17 into the valve body 20 NOTE There are two seat seal rings and 2 carriers and they are interchangeable Ifthe seats are not being replaced install the better of the two seats in the acme threaded end of the valve Grease the face of the seat seal ring 18 Grease the valve ball 19 and install the better side in the acme threaded end of the valve body 20 Install the other seat seal ring 18 and carrier 17 into the valve body 20 and in firm contact with the valve ball 19 44 10 11 12 14 16 Install the bleed adapter to valve body o rings 25 and 26 in the bleed adapter end plate 24 Install the bleed a
3. Flush and Lubricate without Disassembly 10 11 Operate the translation handle so that the socket adapter is withdrawn about half way into the too Place the retriever head end down on a clean surface Add solvent Pour approximately one pint 1 2 liter of solvent into the retriever inner barrel Turn the retriever to a 45 angle and rotate the entire tool slowly While holding the retriever at an angle slowly rotate the translation and rotation handles about one full turn in each direction Turn the retriever end for end With the retriever head end up let the solvent drain out Repeat steps 1 through 5 The retriever head end should again be placed down on a clean surface Pour SAE 30 weight motor oil into the retriever barrel a minimum of four ounces 100 grams Turn the retriever to a 45 angle Operate the rotation and translation handles to coat the surfaces with oil Turn the retriever end for end to drain the oil Test the retriever operation Ifthe retriever still has a gritty feel and sound after this cleaning procedure it must be disassembled for thorough cleaning and lubricating Retriever Disassembly and Cleaning See Figure 2 30 Figure 2 Loosen and remove two set screws 1 which are located on the Outer Barrel 7 near the Hammer Nut using a 3 16 Allen Wrench Loosen and remove the Hammer Nut assembly 2 using the Spanner Wrench provided Inspect the O ring o
4. Phone 1 562 949 0 Serial Number ah i COSASCO MODEL RSL RETRIEVER AND SERVICE VALVE dj USER MANUAL mk _ 11841 E Santa Fe Springs nith PVENU Section 1 0 2 0 3 0 4 0 6 0 7 0 8 0 9 0 10 0 TABLE OF CONTENTS Contents INTRODUCTION SAFETY CHECKLIST RETRIEVER amp SERVICE VALVE CONSTRUCTION amp OPERATION RETRIEVAL OF SOLID OR HOLLOW PLUG ASSEMBLIES INSTALLATION OF SOLID OR HOLLOW PLUG ASSEMBLIES UNDER PRESSURE RETRIEVER BACK PRESSURING RETRIEVER amp SERVICE VALVE SPECIAL TOOLS RETRIEVER MAINTENANCE 3600 PSI SERVICE VALVE MAINTENANCE 6000 PSI SERVICE VALVE MAINTENANCE gt age 31 37 il SECTION 1 0 INTRODUCTION The Rohrback Cosasco Systems RSL Retriever is the newest innovation from the leader in high pressure access equipment This precision tool allows safe easy insertion and removal of various equipment and tools through the industry standard Rohrback Cosasco Systems Access Fitting while the pipeline or vessel is under pressure Used in conjunction with the Rohrback Cosasco Systems Service Valve system pressure is safely ported into the tool which allows the valve to be opened and the retrieval operation to be performed Rotation and translation in and out of the fitting is controlled by two adjustable handles movement or telescoping of t
5. and 8 Open the service valve ball Install the retriever and engage the socket adapter in the same manner as described previously in Section 4 paragraphs 8 through 14 26 10 Pressure equalize the retriever the same manner as described previously in Section 4 paragraph 15 After pressure equalization is achieved slowly turn the rotation handle in a counterclockwise direction thus loosening the pipe plug Retrieve the pipe plug Continue to turn the rotation handle in a counterclockwise direction until the pipe plug is disengaged from the pipe plug assembly then draw the pipe plug into the retriever by rotating the translation handle counterclockwise Close the service valve Open the bleed valve and bleed off pressure Using the brass hammer tap loose the retriever hammer nut and unscrew fully WEAR SAFETY GLASSES Lift the retriever from the service valve Rotate the translation handle clockwise to expose the socket adapter the attached pipe plug adapter and the pipe plug Remove the adapter and the pipe plug from the socket adapter pilot Reinstall the retriever on the service valve and remove the solid plug assembly n the same manner as described previously in Section 4 paragraph 9 to 23 28 SECTION 8 0 RETRIEVER MAINTENANCE The maintenance interval required by the RSL retriever will vary depending upon the service to which it 1s subjected Certain fluids will wash out all lubricant from the retriever afte
6. Rotation Shaft Seal Carrier assembly 1 1 12 13 onto the Rotation Shaft 1 Again the cup end of the seal goes on the shaft first Gently roll the seal onto the shaft using care not to damage the lip of the seal Once on the shaft slide all the way forward Slide the Seal Back up Ring 14 behind the Seal Carrier 11 The end with the smaller outer diameter goes onto the shaft first Slide the Rotation Bearing Assembly 15 behind the Seal Back up Ring 14 NOTE The bearing race with the smaller inner diameter goes on the shaft first Slide the Cap 16 over the Rotation Shaft 1 Push all the way on until the shoulder on the Rotation Shaft 1 is flush with the top surface of the Cap 16 34 J Install the Rotation Shaft Bearing Sleeve 17 into the annular space between the Cap 16 and the Rotation Shaft 1 k Place the Rotation Thrust Bearing 19 onto the Rotation Shaft 1 on the top of the Cap 16 l Place the Rotation Ring 18 onto the hex on the Rotation Shaft 1 Tighten the Set screw to approximately 10 ft lbs m Place the Translation Thrust Bearing 7 onto the Translation Shaft 4 on top of the Rotation Ring 18 n Place the Drive Socket 8 onto the Translation Shaft 4 so that the hole in the Drive Socket 8 lines up with the hole in the Translation Shaft 4 Drive the Roll Pin 20 into the lined up holes with a hammer 10 Test the Cap Assembly by rotating the Translation and Rota
7. YOUR SOLE REMEDY SHALL BE REPAIR OR REPLACEMENT AS PROVIDED ABOVE IN NO EVENT WILL RCS BE LIABLE TO YOU FOR ANY DAMAGES WHETHER BASED UPON BREACH OF WARRANTY BREACH OF CONTRACT NEGLIGENCE STRICT TORT OR ANY OTHER LEGAL THEORY INCLUDING ANY LOST PROFITS LOST SAVINGS OR REVENUE LOSS OF USE OF THE PRODUCT OR ANY ASSOCIATED EQUIPMENT LOSS OF SUBSTITUTE EQUIPMENT OR OTHER INCIDENTAL OR CONSEQUENTIAL DAMAGES ARISING OUT OF THE USE OF OR INABILITY TO USE SUCH PRODUCT EVENIF RCS OR AN AUTHORIZED RCS DISTRIBUTOR HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES OR FOR ANY CLAIM BY ANY OTHER PARTY INCLUDING CUSTOMERS OF THE ORIGINAL USER Any action for breach of warranty must be commenced with three 3 months of the expiration of the warranty period To obtain Limited Warranty Service or other assistance contact your nearest RCS office or distributor or contact RCS Customer Service directly at Rohrback Cosasco Systems Inc Tel 562 949 0123 11841 East Smith Avenue Fax 562 949 3065 Santa Fe Springs CA 90670 09 5 U S A C WPS0 RSO WARRANTY 49 431314138 154 O9SVSO9 AT8W3SSY 83318138 YSN YINHO1I1VO SONIHdS 34 VINYS WALSAS 0951502 XOVAUHOH J E RR 7 nazw 2 1811 SLHVd NOLLAINOS30 889 ASSY YILAWOW 133205 H38WNN Lava NOILVLOY L1YHS 13VHS NIOILVISNV8L LSNYHL 13 NOILWISNVUL 343318 ONIYWV38 NOLLWISNYAL L4VHS 14VHS NOLL
8. and be sure that the threads engage properly to prevent cross threading b If cross threading does occur the plug assembly will have to be removed observing all of the procedures as outlined in Section 4 Retrieval of Solid or Hollow Plug Assemblies under Pressure Also see Section 7 Retriever and Service Valve Special Tools Tap Assembly 125116 To complete the engagement of the plug assembly to the access fitting body turn the rotation handle 14 or 15 turns The plug assembly should be barely or lightly seated Tighten only 1 4 turn after the primary packing contacts its seat within the access fitting body This will leave sufficient room for travel for orientation using the index mark mentioned previously If the plug assembly does not seat properly it may be caused by one of the following a Damaged plug assembly thread Remove and repair with thread die assembly 125112 or replace the plug assembly b Damaged access fitting body thread The use of thread tap assembly part number 125111 is recommended Sand or chips in the threads Use the thread brush assembly 125116 surge tube assembly 123672 or the magnetic swab assembly 121870 d Monitoring or preventing device hitting the bottom of the pipe This will require replacement with a shorter device e Monitoring or preventing device hitting an obstruction at the access fitting body base This may be due to improper weld procedures or noncentricity of access
9. bleed screw on its seat before the retaining lock nut is securely tight Check the service valve for smooth operation by opening and closing the ball Pressure test the service valve Rated working pressure is 6000 PSI 413 BAR at temperatures to 200 F 93 C 27 26 20 24 23 22 21 20 19 18 17 16 15 14 13 12 FIGURE 10 1 RBS 6000 SERVICE VALVE Bleed Valve O ring Bleed Adapter to Valve Body O ring Bleed Adapter to Valve Ball Carrier Plate Bleed Adapter End Screw Allen Head Cap 1 2 Screw Allen Head Cap 1 2 Valve By pass Body Valve Ball Ring Seat Seal Carrier Ball O ring Retainer to Body Retainer Hammer Nut to Body Screw Allen Socket Head Cap 5 8 Nut Hammer O Ring Hammer Nut Seal O ring O ring Bonnet to Valve Body Ring Thrust Seal Stem Back up Ring Stem Bonnet Plug Pipe Plate Position Stop Screw Allen Head Cap 3 8 Stem Handle Valve Ball Control Handle Extension Not Shown 46 1 each l each l each l each l each 2 each l each l each l each l each 2 each 2 each l each l each 16 each 1 each 5 each l each l each l each l each l each l each l each l each 1 each l each FIGURE 10 1 RBS SERVICE VALVE UR SS S Cum 287 AM aa KK lt IDQ NS II 4 DA 2 sax 07 Q sreop 1 NOT SHOWN BLEEDERS ARE SHOWN ROTATED 902 ANGLE FROM HORIZONTAL 48 LIMITED WAR
10. damaged it should be repaired by brushing or filing The use of the optional heavy protective cover manufactured of steel 1s recommended since 1t 1s more durable Loosen the plug assembly It is recommended that prior to removing either the plastic or steel pipe plug the plug assembly be unfrozen from its seat Using either a 1 1 8 socket or a 1 1 8 box end wrench loosen the plug assembly by turning counterclockwise to a maximum of 1 4 turn DO NOT loosen beyond the 1 4 turn maximum or leakage may result If leakage begins tighten the plug as required to stop the leakage Remove the pipe plug from the plug assembly The solid plug assembly uses a stainless steel pipe plug with a 1 2 square head which acts as a secondary seal Hold the plug assembly hex with a box end wrench to prevent it from backing off while using a crescent wrench to turn the pipe plug slightly counterclockwise If for any reason there is pressure behind the plug which after one or two minutes has not been bled off loosen the steel pipe plug 1 8 turn more If pressure bleeds off remove the pipe plug if it has not re tighten the prpe plug and refer to Section 7 Retriever and Service Valve Special Tools Section 7 4 The hollow plug assembly uses a plastic pipe plug as a dust cover only therefore no bleed off will be required Check the service valve Inspect the o ring at the hammer nut end for nicks cuts abrading It is recomme
11. fitting body with the cut or hot tapped hole into the pipe This condition will require the reaming of the hole into the pipe with a hot tap square end mill part number 612016 7 12 f Incorrect access fitting body weld procedures This can cause body distortion or warpage due to excessive heat or improper after weld stress relieving If distortion or warpage appears minor the use of access fitting body seat reamer 125125 is recommended If distortion or warpage is major a new access fitting body should be 18 De 13 14 16 17 18 welded to the line using the proper welding procedures See Manual 740074 Trepanning Positioning and Welding Procedures Indications of any of the above causes will be noted after retriever bleed off is accomplished as described in paragraph 13 The indications may be an unstable pressure gauge reading the hearing of pressure still entering the retriever or feeling the lack of pressure load on the seals as evidenced by a lack of friction If the plug assembly cannot be seated and sealed 1t may be necessary to leave the service valve on the line until a later shut down when repairs can be made If this becomes necessary a service valve blanking plug 127391 should be placed on the service valve after the retriever has been removed to prevent possible leaks or inadvertent opening of the service valve Retriever bleed off Open the bleed valve and drain the retriever product pr
12. or side position For top locations remove the service valve port plug and then open the service valve bleed valve one or two turns Watch the pressure gauge a gradual drop to zero should be indicated at which point the retriever should have bled off pressure completely This may take up to two minutes to complete Close the bleed valve When the retriever is completely depressurized disconnect the diverter hose assembly and close the bleed valve WEAR SAFETY GLASSES Tap loose the retriever hammer nut using the brass hammer It may be advisable for two men to help each other in removing the retriever from the fitting Lift the retriever to remove from the service valve Do this carefully If the product media 1s liquid a certain amount will ooze at the disconnect Junction or from the retriever Check retriever operation Operate the retriever rotation and translation handles If it seems difficult to operate or feels or sounds gritty cleaning and lubricating before further use is recommended 16 SECTION 3 0 INSTALLATION OF SOLID OR HOLLOW PLUG ASSEMBLIES UNDER PRESSURE The following procedure assumes the service valve is installed on the access fitting body and is in the closed position The retriever must be in a cleaned and lubricated condition 5 1 Prepare the plug assembly a Visually inspect the plug assembly threads and clean or repair 1 necessary Minor repai
13. the retriever bleed valve and allow bleed off for approximately twenty seconds Normally this is sufficient time for debris to be flushed from the access fitting body threads 23 10 11 12 Close the retriever bleed valve Remove the diverter hose assembly Retrieve the tap Turn the rotation handle counterclockwise for about 14 to 17 turns while maintaining slight counterclockwise pressure on the translation handle until the tap threads are fully disengaged from the access fitting body threads Once the tap is clear of the threads rotate the translation handle counterclockwise until it stops to draw the tap into the retriever Close the service valve ball and the service valve bleed screw Bleed and remove the retriever Open the retriever bleed valve and allow pressure to bleed off completely Using the brass hammer tap loose and fully unscrew the retriever hammer nut WEAR SAFETY GLASSES Lift the retriever from the service valve Remove the tap Unscrew the tap from the socket adapter pilot NOTE If the tool flutes have a large amount of debris it is recommended that the surge tube assembly or thread brush assembly be used to clean the access fitting body and threads prior to reinstalling the plug assembly See part 7 3 and or 7 2 following Thread Brush Assembly 125116 The thread brush assembly is used to clean small amounts of debris from the access fitting body threads l Attach the thread brush assemb
14. 22 if they were removed for seal replacement Back off the bleed screws several turns before tightening the large bleed screw retaining lock nuts This avoids bottoming out the bleed screws on their seats before the retaining lock nuts are securely tight Check the service valve for smooth operation by opening and closing the ball 12 Pressure test the service valve Rated working pressure is 3600 psi 248 BAR at temperatures to 200 F 93 C 39 40 49 ni F BER BEEESCECRRRESES SRARARPARAFEPEERESEECEDCECEEOSE o 5 9 Sw GO O G G A 4 5 GE SE 1 0d T vi o SECEE 4 i Vy 6 soa Y R AN w U 5 2 0 RINGS 1 BACK UP RING PER PAR a REPAIR KIT PART KIT 601008 e SEAL KIT PART KIT 60 009 FOR BLEEDER VALVE IN SEAL A REPAIR KIT A ormat NIT PART KIT 601001 601 NA 2 4 Pe E 4 ORW 4 AY HO nse Al ii 42 SECTION 10 0 6000 PSI SERVICE VALVE MAINTENANCE The maintenance interval required for the service valve will be determined by the media acting upon the valve Sand grit or metal chips may damage seats causing leaks which will require seat replacement Occasional lubrication will be necessary to reduce opening torque The use of a synthetic lubricant such as Rohrback Cosasco Systems 201688 15 recom
15. RANTY Rohrback Cosasco Systems Inc RCS warrants this RCS Corrosion Monitoring Product Product to be free from defects in material and workmanship for a period of eighteen months from the date of purchase from RCS or an authorized RCS distributor or one year from the date first placed in service whichever comes first with the following exceptions RCS Corrosion Monitoring Products routinely exposed to process fluids under a variety of operating conditions Because RCS cannot anticipate all possible combinations of process fluid composition operating conditions and materials of construction RCS makes no warranty as to compatibility of its products in the application conditions CORROSOMETER probe sensing elements CORRATER electrodes and COSASCO coupons are designed to corrode As corrosion proceeds the structural integrity of the corroding surfaces is unavoidably affected RCS makes no warranty and specifically disclaims all warranties as to structural integrity of any of these products left exposed to the process beyond their intended service life RCS does not warrant Products not manufactured by RCS This Limited Warranty does not include service to repair damage to the Product resulting from shipping improper installation or use accident disaster abuse attempts to service the Product by unauthorized personnel or non RCS modification of the Product Should RCS determine that the Product has failed withi
16. WISNVUL 7 36 H3IHHVO dn X0Vv8 1 35 ONIY 140HS NOLLYTSNYHL LSNYH1 H3HSYM NDOIIS 15 140HS NOLLVISNWAL 3 133206 140049 22252 21 290800 LAVHS NOLLVISNYAL TVASOHVA 590019 149HS NOLLVLOY 1438 H3IHUYO 14VHS NOLLWLOY TVaSIHVA S 622 2 DNIY O 9015 ONIHSNA 14VHS NOLLYLOH LSNUHL ONIUY38 09 OINOYLIN dvI ONIWV38 NOLLW LOY 313315 ONIHY38 VHS NOLLWLOY 3A190 ALAVHS NOLLVLOY ISNYHL H3HSYM 940019 SZ X 52 TION Nid 080019 NOLLYTSNYHL 39N11 9019 Y31AVOV 950019 650019 09 OINOBLIN 240019 NOILYLOB 38N11 031 02 NIL 09 OINOYLIN 52 H30VdS YIMOT 008 38NL 150019 850019 550012 09 OINIOHLIN 626 40123 02 INN Y3WWYH 150019 OPO LAN HZAWYH 2242 in 1 m MP waz 117 7777777777777771 Kar 2 O LLL EEES NM LiL iLL A N N N 1777747 7777 77 ST PTA grm IQ a x p NNS N I CA U Pt p wali 1031310385 3SIMY3HLO SSIINN ILON HLONAT SOULS W 169 0009 0009 1540052 0087 ONLLWY 34NSS3Yd GHVONvLS U HL9N31 En TAXXX 020009 SMOT104 Sv SI HJ8WNN LHvd a_4 ja Re A W M R SZOS Na o 2 SS ETT
17. cap screws 19 secure the hammer nut assembly 20 to the valve body 1 9 Remove the hammer nut assembly 20 and retainer 16 from the valve body 1 exposing the first of two seat seal rings 15 and their carriers 13 Remove both the seat seal ring 15 and its carrier 13 from the valve body 1 Remove the retainer to access fitting body o ring 18 and retainer to valve body o ring 17 which are now accessible 3 Remove the 5 16 Allen head cap screw 4 securing the valve handle 5 to the square head of the stem by using a 1 4 Allen wrench Remove the position stop plate 25 which is now exposed 4 Remove the four 7 16 Allen head cap screws 28 and the two 1 2 Allen head screws 24 retaining the bonnet 2 to the valve body 1 by using a 5 16 and 3 8 Allen wrench respectively Remove the bonnet 2 and stem intact from the valve body 1 Remove the bonnet to valve body o ring seal 11 which is now exposed 6 Remove the valve ball 12 from the valve body 1 Remove second seat seal ring 15 and its carrier 18 from the valve body Remove the carrier seal 14 which is now accessible 37 Further disassemble the stem 3 from the bonnet 2 previously removed in paragraph 5 and remove the stem seal 9 its back up ring 8 and the thrust ring 10 which are now exposed Remove the by pass or vent valves 22 only if necessary for seal replacement To remove turn the larg
18. dapter end plate 24 onto the valve body 20 using the 5 8 Allen head cap screws 14 by using a 1 2 Allen wrench DO NOT tighten them securely at this stage Partially assemble the bonnet 7 by installing back up ring 8 insert stem seal 9 and o ring seal 11 in the bonnet 7 Install the thrust washer 10 on to the stem 3 in bonnet 7 Position the bonnet and stem into the valve body 20 stem recess Carefully position the bonnet 7 onto the valve body 20 ensuring that the thrust washer 10 is eased into position concentric with the o ring 11 Torque the six 1 2 Allen head cap screws 22 23 retaining the bonnet 7 to the valve body by using a 3 8 Allen wrench to 50 ft Ib Install the position stop plate 5 over the top of the stem 3 and position the valve ball handle 2 onto the square head of the stem 3 Ensure that handle positioning points are away from the hammer nut end when the valve ball is in the open position Tighten the 3 8 Allen head cap screw retaining the handle 2 to the stem 3 by using a 5 16 Allen wrench Torque the eight 5 8 Allen head cap screws 14 that were initially installed as indicated in paragraph 8 to retain the bleed adapter end plate 24 to 90 ft Ib Install the by pass 21 or vent valve 27 if it was removed for seal replacement Back off the bleed screw several turns before tightening the large bleed screw retaining lock nut This avoids bottoming out the
19. e bleed screw retaining lock nuts counterclockwise and completely disengage from the service valve body 1 To disassemble the bleed screws from their retaining lock nuts it is necessary to remove the roll pins and the small nylock hex nuts from the bleed screw tops By turning clockwise on the bleed screws they will thread out through the bottom of their retaining lock nuts Service Valve Assembly 6 Clean all parts Examine all seals and o rings It is highly recommended that seals and o rings be replaced each time the service valve is disassembled and reassembled Even then prior to assembly they should be thoroughly inspected for nicks cuts or abrasions Install the carrier seal 14 one of the two set seal rings 15 and its carrier 13 into the service valve body 1 NOTE There are two seat seal rings 15 and carriers 13 and that they are interchangeable Ifthe seats 15 are not being replaced install the better of the two seats 15 in the acme threaded end of the service valve Grease the face of the seat seal ring 15 Grease the valve ball 12 and install the better side in the acme threaded end of the valve body Install the other seat seal ring 15 and carrier 13 into the valve body 1 and in firm contact with the valve ball 12 Lubricate the swivel on the hammer nut adapter assembly 20 Install the retainer to valve body o ring 17 and retainer to access fitting body o ring 18 on
20. engage Rotate the translation handle counterclockwise to draw the plug assembly into the retriever Connect the retriever to the service valve First examine the o ring at the hammer nut end of the retriever for damage and replace if nicked cut or abraded Lift the retriever and place it on the service valve Turn the hammer nut clockwise until the retriever is securely seated on the service valve Use the brass hammer to tap a secure connection WEAR SAFETY GLASSES Ensure that the bleed valves are fully closed on both the retriever and service valve 17 Slowly open the service valve equalizing valve to pressurize the retriever Before proceeding further wait until the retriever is fully pressurized Open the service valve ball and close the equalizing valve Rotate the translation handle clockwise until it stops At this point the plug assembly is resting on the top of the access fitting body Engage the plug assembly to the access fitting body a While maintaining clockwise pressure on the translation handle rotate the rotation handle clockwise to thread the plug assembly into the access fitting body Maintain clockwise pressure on the translation handle to insure that the socket adapter hex remains over the plug assembly If the plug assembly does not start threading properly turn the rotation handle counterclockwise one full turn then clockwise again to engage the threads Do not use excessive force
21. essure and media residue into a container or safe area until all pressure has been relieved Disengage the socket adapter from the plug assembly Disconnect the diverter hose assembly ifit was used Rotate the translation handle counterclockwise to back the hex off of the access fitting body The translation handle should move about 90 counterclockwise Rotate the rotation handle counterclockwise a minimum of 5 turns to unthread the socket adapter assembly from the plug assembly If the hex is properly backed off of the plug assembly the rotation handle will rotate fairly easily If itis difficult to rotate then make sure the translation handle 15 rotated counterclockwise as far as it will go Loosen the retriever hammer nut and remove the retriever Using the brass hammer tap loose the hammer nut and unscrew fully WEAR SAFETY GLASSES Lift the retriever from the service valve do this carefully if the product media is a liquid because a small amount of product will be lost at the disconnect junction Install the stainless steel pipe plug Liberally grease 1 2 stainless steel pipe plug and install securely into the solid plug assembly NOTE Hollow plug assemblies use a red plastic pipe plug therefore greasing is unnecessary Orient the plug assembly The index mark filed as mentioned in paragraph 5 1 d must now be aligned to the product flow direction Turn the plug assembly hex clockwise until the mark aligns with
22. f the retriever fails to pressurize after 2 turns back off the plug assembly by additional 2 counterclockwise turns of the rotation handle Ifthe retriever still has not balanced wait for 10 to 15 minutes DO NOT BACK OFF THE PLUG ASSEMBLY MORE THAN A TOTAL OF 4 TURNS d The retriever bleed valve can be opened to test for the presence of pressure the retriever If after waiting the required 10 to 15 minutes the pressure has not entered the retriever the plug assembly or the retriever has encountered an obstruction or accumulation of dirt or debris Back pressuring the retriever should be the next step for relieving the obstruction See Section 6 Retriever Back Pressuring Retrieving the plug assembly from the access fitting body a When the retriever has pressure equalized with the line the plug assembly can be disengaged from the access fitting body b Turn the rotation handle counterclockwise approximately 15 or 16 turns to completely disengage the plug assembly from the access fitting body Ensure that the socket adapter hex and the plug assembly hex remain engaged during this operation by maintaining clockwise pressure on the translation handle Disengagement will allow the socket adapter pilot to unscrew from the plug assembly leaving the plug assembly in the access fitting body Refer to paragraphs 12 and 14 After the plug assembly 15 removed from the access fitting body rotate the translation handle co
23. fitting body by using line pressure l 4L 6L 7L 8L OL 10L Connect the surge tube assembly Life the surge tube assembly and place the hammer nut end on the service valve Turn the hammer nut clockwise untl the surge tube assembly is securely seated Use the brass hammer to tap a secure connection WEAR SAFETY GLASSES Close the surge tube bleed valve The same optional diverter hose assemblies used on the retriever and service valve are available for connection to the surge tube assembly For LOW PRESSURE lines pressures lower than 250 psi 17 BAR see L steps below For HIGH PRESSURE lines pressures higher than 250 psi 17 BAR see H steps below Open the service valve quickly Open the surge tube bleed valve and allow flow for approximately twenty seconds Close the surge tube bleed valve Close the service valve Open the surge tube bleed valve and allow the surge tube pressure to bleed off Close the surge tube valve Repeat steps 4L through 9L at least two more times 7 4 AH 6H 7H 8H 9H 10H 11 Open the service valve equalizing valve This will reduce the torque required to open the service valve Open the service valve quickly and then close the service valve equalizing valve Open the surge tube bleed valve and allow flow for approximately twenty seconds Close and open the surge tube bleed valve at least two more times and each time allow flow for approx
24. he Rotation Tube 4 so that the ends are flush with each other Slide the Socket Adapter assembly 3 into the Translation Tube so that the hole in the top of the Socket Adapter Assembly lines up with both the spiral slot in the Translation Tube and the longitudinal slot in the Rotation Tube Drop the Drive Pin 6 into the hole in the Socket Adapter Assembly Carefully slide the completed tube assembly into the Outer Barrel 7 Once the tube assembly is fully inserted stand the retriever head end down Carefully rotate the Translation Tube 5 and the Rotation Tube 4 until they line up with the head assembly drive shafts You will feel them drop into place and they will only rotate if the appropriate drive shaft on the head assembly 1s rotated Insert the Lower Spacer into the Outer Barrel 7 The protruding flange on the Spacer must be positioned between the Translation Tube 5 and the Rotation Tube 4 Thread the Hammer Nut Assembly 2 into the Outer Barrel 7 Tighten with the Spanner Wrench to approximately 20 ft lbs Do not over tighten this connection Install and torque the two Set Screws 1 to approximately 100 in lbs Check the tool for proper operation Rotate the Translation handle and the Rotation handle and assure the Socket Adapter moves in and out with no binding Pressure test the tool using a non corrosive liquid such as motor oil Rated working pressure 1s 2500 psi 17 2 MPa for the model RSL 2500 or 6000 p
25. he tool body is necessary and best of all no gt hydraulic pumps or hoses are required This tool can be used with the industry standard Rohrback Cosasco Systems access fitting DER and service valves with no adapters required any timo any place Each RSL Retriever Kit is furnished with service tools and spare parts in a sturdy field service box to provide compact easy storage and portability The new COSASCO RSL 2500 and 6000 Retrievers utilize a compact non telescoping design that provides the highest level of safety and the advantage of a short tool length without the inconvenience of hydraulic pumps and fluid Best of all it is compatible with all COSASCO 2 High Pressure Access fittings without the need for special adapters Access under pressure for Bottom of the Line monitoring locations requires minimal clearance avoiding the need to produce access pits or to raise the pipe work The design without the use of sliding seals provides for easy tool maintenance and cleaning The elimination of sliding seals reduces the cost of seal replacement 6 SECTION 2 0 SAFETY CHECKLIST Safe operation requires a minimum of 2 trained operators Do not use this retrieval equipment unless you have been trained in its safe operation Ifit has been longer than 90 days since your last operation you should review the manual and first practice on a dummy fitting prior to use Make sure you have complied with all plant safety
26. imately twenty seconds Each time the surge tube valve is in the open position partially close and then fully open the service valve This will help to remove solids or particles from the seat area or carrier Close all valves Close the surge tube bleed valve the service valve and the service valve equalizing valve Open the surge tube bleed valve and allow the surge tube pressure to bleed off Close the surge tube bleed valve If the optional diverter hose assembly 15 being used during the operation it should be removed at this time Remove the surge tube assembly Using the brass hammer tap loose and fully unscrew the surge tube hammer nut WEAR SAFETY GLASSES Lift the surge tube assembly from the service valve Steel Pipe Plug Adapter 125115 The steel pipe plug adapter is used to install or allow retrieval of the 1 2 steel pipe plug while plug assemblies are under pressure This tool is used in cases where bleed off cannot be accomplished The procedure described for the steel pipe plug adapter differs from the other tools described in this section in that the service valve 18 assumed not to be installed and that the plug assembly is assumed to be present within the access fitting body 1 Attach the pipe plug adapter to the square head of the pipe plug and tighten the Allen head set screws Install the service valve onto the access fitting body in the same manner as described previously in Section 4 paragraphs 6 7
27. imum of 5 turns to unthread the socket adapter assembly from the plug assembly If the hex is properly backed off of the plug assembly the rotation handle will rotate fairly easily If it is difficult to rotate then make sure the 8 translation handle s rotated counterclockwise as far as it will go h Rotate the translation handle counterclockwise to move the socket adapter away from the plug assembly Bleed the pressure from the tool using the bleed valve on the retriever the bleed valve on the service valve or both Insure that the pressure 1s reduced to zero on the pressure gage on the retriever 1 The retriever and service valve may now be removed from the access fitting Replace the pipe plug and protective cover on the access fitting body 10 SECTION 4 0 RETRIEVAL OF SOLID OR HOLLOW PLUG ASSEMBLIES The following procedure is for retrieval of solid or hollow plugs from access fitting bodies under pressure The operator should first determine pressure temperature and the type of media Any action which could vary pressure such as surges caused by the opening or closing of valves or chokes should be delayed until after the retrieving operation has been completed 1 Stroke and circumferential clearance Determine if the retriever has an adequate stroke clearance and that the entire operation has adequate circumferential clearance a Clearance beyond the top of the access fitting body s required for installat
28. ion and operation of the retriever and service valve The following recommendations should give adequate clearance 18 stroke A feet 1 2 meters 25 stroke 2 5 feet 1 5 meters 37 stroke 6 feet 1 8 meters b In addition circumferential to allow movement of the operator s and free movement of the equipment is required The following recommendations should give adequate clearance Above ground level From the center line of the access fitting a radius of at least three feet should be maintained Below ground level A minimum diameter culvert of manhole of four feet should be provided with the fitting placed off center one foot from the culvert wall Note that both the translation handles and rotation handles are adjustable in radius to allow use in close radial proximity to other objects However using the handles in this way will result in slower operation of the tool 2 Adjust the socket adapter assembly For solid or hollow plug assemblies the socket adapter should be set in the second and fourth holes from the hex end When retrieving the hot tap plug assembly with the 14 or 18 stroke retriever the socket adapter must be in the first and third holes from the hex end 3 Remove the access fitting cover if present After removing the cover check the access fitting body to ensure that the o ring contact area 18 clean and that the acme thread is in good condition 11 6 If the thread has been painted or
29. ise pressure should be maintained on the translation handle to move the carrier forward as the thread engages the plug assembly but not so much pressure that the hex on the socket adapter drops over the plug assembly This operation is a little tricky at first but is fairly simple once the concept is understood and practiced a few times While rotating the rotation handle maintain enough clockwise pressure on the translation handle to allow the pilot adapter to thread into the top of the plug assembly but not so much pressure that the hex socket drops over the plug assembly If the rotation handle becomes difficult to turn rotate the translation handle slightly clockwise Ifthe rotation handle becomes easy to turn then continue threading it into the plug If it remains difficult then the hex has probably engaged the plug at which point you must rotate the translation handle counterclockwise to disengage the hex and then continue clockwise with the rotation handle Once properly engaged to the plug thread the socket adapter into the plug assembly about 4 or 5 turns Close bleed valves Ensure that both the retriever and service bleed valves are closed Connect the socket adapter hex Rotate the translation handle clockwise to drop the hex over the plug assembly The rotation handle will need to be turned slightly during this operation in order to line up the hex with the plug You will know when it is aligned and dropped onto the plug
30. len head cap screws retaining the bonnet 7 to the valve body 20 by using a 3 8 Allen wrench Remove the bonnet and stem 8 and 7 intact from valve body 20 Remove the bonnet to valve body o ring seal 11 which is now exposed 6 Remove the valve ball 19 from the valve body 20 10 3 10 11 Remove both the second seat seal ring 18 and its carrier 17 from the service valve body 20 Remove the eight 5 8 Allen head cap screws 14 retaining the hammer nut adapter assembly 18 to the valve body 20 by using a 1 2 Allen wrench Remove the hammer nut adapter assembly 18 Remove the hammer nut to body retainer 15 from the valve body 20 Further disassembly of the stem 3 from the bonnet 7 previously removed in paragraph 5 is done by removing the stem seal 9 its back up ring 8 its o ring 11 and the thrust ring 10 which are now exposed Remove the by pass 21 and bleed valve 27 only if necessary for seal replacement To remove turn the large bleed screw retaining lock nut counterclockwise and completely disengage from the service valve body 20 To disassemble the bleed screw from its retaining lock nut it is necessary to remove the roll pin and the small nylock hex nut from the bleed screw top By turning clockwise on the bleed screw it will thread out through the bottom of its retaining lock nut Seal replacement can now be accomplished Service Valve Assembly
31. ll parts in a suitable solvent Install new seals and O rings in the seal carriers Note that the opening on the high pressure seals must face the nearest opening in the seal carrier see figure 4 Carefully roll the seal into the groove until it snaps into place 33 Figure 4 8 Lubricate the seals and O rings with a suitable grease such as Dow 44 supplied Also generously pack both bearings with grease Coat all inner surfaces with grease 9 Reassemble the cap assembly Refer to figure 3 for orientation Start with the Translation Shaft 4 and assemble as follows a d h Slide the assembled Translation Seal Carrier Assembly 5 9 10 onto the Translation Shaft 4 The cup end of the seal goes on the shaft first Gently roll the seal onto the shaft using care not to damage the lip of the seal Once on the shaft slide all the way forward Slide the Seal Back up Ring 6 behind the Seal Carrier 5 Slide the Translation Bearing Assembly 2 behind the Seal Back up Ring 6 NOTE The bearing race with the smaller inner diameter goes on the shaft first Slide the Rotation Shaft 1 over the Translation Shaft assembly Push it down until the O ring seats on the inner surface of the Rotation Shaft and the Rotation Shaft completely covers the Translation Shaft assembly Slide the Translation Shaft Bearing Sleeve 3 into the annular space between the Translation Shaft and the Rotation Shaft Slide the
32. ly to the socket adapter pilot threads 2 Connect the retriever Lift the retriever and place it onto the service valve Turn the hammer nut clockwise until the retriever 1s securely seated on the service valve Use the brass hammer to tap a secure connection WEAR SAFETY GLASSES 3 Open the service valve equalizing valve and then open the service valve ball 4 Rotate the translation handle clockwise until the thread brush Just barely contacts the access fitting body Brush the threads Turn the rotation handle in both directions while turning the translation handle clockwise until it bottoms 6 Retrieve the thread brush assembly Beginning with a very slight clockwise rotation on the rotation handle pull the brush straight up and out of the access fitting body by rotating the translation handle counterclockwise 10 Pull the thread brush into the retriever by rotating the translation handle counterclockwise until it stops Close the service valve and the service valve equalizing valve Bleed and remove the retriever Open the retriever bleed valve and allow pressure to bleed off completely Using the brass hammer tap loose and fully unscrew the retriever hammer nut WEAR SAFETY GLASSES Lift the retriever from the service valve Remove the thread brush assembly Unscrew the thread brush assembly from the socket adapter pilot Surge Tube Assembly 123672 The surge tube assembly is used to flush debris from the access
33. mended 101 Sour Gas Service On both the 3600 PSI and 6000 PSI service valves applicable materials comply with the requirements of NACE standard MRO175 Sulfide Stress Cracking Resistant Metallic Materials for Oil Field Equipment As stated in this standard Materials are resistant to but not necessarily immune to sulfide stress cracking under all service conditions Thus when the valve is used in sour environments it must be thoroughly cleaned after use to help prevent corrosion and or damage to internal materials 10 2 Service Valve Disassembly Applicable to 6000 pound service valve kit P N 210262 valve P N 210257 The RBS 6000 Service Valve has a valve ball that is removable only from the service valve hammer nut end access fitting body connection Normally for routine maintenance disassembly instructions indicated in paragraphs 8 and 9 need not be done 1 Loosen and remove the eight 5 8 Allen head cap screws 14 at the acme thread end using a 1 2 Allen wrench 2 Remove the bleed adapter end plate 24 from the valve body 20 exposing the first of two seat seal rings 18 and their carriers 17 Remove the seat seal ring 18 and its carrier 17 from the valve body 20 3 Remove the 3 8 Allen head cap screw 4 securing the valve handle 2 to the square head of the stem 3 by using a 5 16 Allen wrench Remove the position stop plate 5 which is now exposed 4 Remove the six 1 2 Al
34. n the inboard end of the Hammer Nut assembly and replace if required Carefully slide the Socket Adapter Assembly 3 the Rotation Tube 4 and the Translation Tube 5 out of the Outer Barrel 7 Take care to preserve the Lower Spacer which is located between the Translation Tube 5 and the Rotation Tube 4 Remove the Drive Pin 6 which is protruding from the slot in the Rotation Tube 4 This will allow the Socket Adapter Assembly to be removed from inside the Translation Tube 4 Loosen and remove two set screws 1 which are located on the Outer Barrel 7 near the Bleed Valve Assembly using a 3 16 Allen Wrench Loosen and remove the Head Assembly 8 using the large jaw Monkey Wrench provided Clean all parts using a suitable solvent Flush out any debris from the Head Assembly 8 The Head Assembly will not need to be disassembled as long as it is operation 31 8 4 10 11 12 14 smoothly without any grinding feel and s not leaking See section 8 4 if the Head Assembly needs to be overhauled Apply grease Dow 44 Bearing Grease is provided to all moving parts and the O ring on the Hammer Nut Assembly 2 Thread the Head Assembly 8 onto the end of the Outer Barrel 7 Tighten to approximately 20 ft lbs using the large jaw Monkey Wrench Do not over tighten the Head Assembly Install the two Set Screws 1 and torque to approximately 100 in lbs Slide the Translation Tube 5 into t
35. n the warranty period RCS will as its option repair or replace the Product at no charge except as set forth below Repair parts will be either reconditioned or new All replaced parts and Products become the property of RCS To obtain Limited Warranty service you must contact RCS s Customer Service Department to obtain a Return Authorization Number and Shipping Instructions NO PRODUCTS WILL BE ACCEPTED FOR RETURN WITHOUT A RETURN AUTHORIZATION NUMBER You agree to be solely responsible for all costs of removing the Product from service shipment including insurance to and from the designated RCS Service Center and reinstallation RCS will be responsible for the cost of return shipment for any valid warranty claim RCS reserves the right to inspect an allegedly defective Product at the place of installation or use If RCS determines that there is a valid claim there will be no charge for such inspection In all other cases any inspection by RCS will be at the rates specified in RCS s then current published Field Service Rate Schedule THE FOREGOING WARRANTIES ARE IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE This Limited Warranty is extended to the original user for industrial use only and is not a consumer product warranty extended under the Magnuson Mass Warranty Act IF THIS PRODUCT 1S NOT IN GOOD WORKING ORDER AS WARRANTED ABOVE
36. nded to inspect and pressure test the service valve periodically to be sure it 1s in good working order as there is a possibility that should a problem occur it will have to be left on the line Connect the service valve to the fitting Lift the service valve assembly and place it on the access fitting body Thread the hammer nut clockwise until the service valve is securely seated Tap the hammer nut tight using a brass hammer WEAR SAFETY GLASSES Close and open the service valve ball to be sure there 1s adequate handle clearance If there 15 not loosen and reposition the handle until adequate clearance 1s obtained The valve should be left in the open position 10 11 13 14 Check the retriever Inspect the thread adapter o ring for nicks cuts and abrading a Operate the retriever Operate the translation handle and rotation handles and check that they operate smoothly without binding or excessive noise To connect retriever Lift the retriever and place it on the service valve Turn the hammer nut clockwise until the retriever is seated on the service valve Tap the hammer nut tight Using a brass hammer WEAR SAFETY GLASSES Connect the socket adapter pilot Rotate the translation handle clockwise to move the socket adapter to the top of the plug Once at the top of the plug rotate the rotation handle clockwise to thread the socket adapter into the plug assembly Slight clockw
37. ody and that it is in the closed position The plug assembly is also assumed to be absent from the access fitting body 7 1 Thread Tap Assembly 125111 The thread tap assembly is used to clean debris from threads to repair thread damage 6 Attach and grease the tap Attach the tool to the socket adapter pilot male thread Apply grease liberally to the cutting edges Lift the retriever and place it on the service valve Turn the hammer nut clockwise until the retriever is securely seated and tightened in place on the service valve Use the brass hammer to make up a secure connection WEAR SAFETY GLASSES Open the service valve equalizing screw and then open the service valve ball Rotate the translation handle clockwise until the tap just contacts the top of the access fitting body Turn the rotation handle two full turns counterclockwise This will help to allow the tap threads to align with the access fitting body threads For thread tap cutting slowly turn the rotation handle clockwise allowing the tool threads to engage the access fitting body threads Continue turning the rotation handle clockwise 14 to 17 turns while maintaining slight clockwise pressure on the translation handle occasionally turn the rotation handle counterclockwise to help the tap threads to clear Do not allow the tap to bottom When the tap operation is completed connect the diverter hose assembly to the retriever bleed valve Open
38. on handle to assure the socket adapter hex stays dropped over the plug assembly rotate the rotation handle counterclockwise slowly System pressure should enter the retriever as seen on the pressure gage on the bleed valve assembly after 1 to 2 turns Once pressure is stabilized 7 continue to turn the rotation handle counter clockwise to completely remove the plug from the fitting This normally takes about 14 rotations and you will often hear and or feel a click sound once each rotation once the plug is out of the fitting e Rotate the translation handle counterclockwise to pull the plug assembly into the retriever tool If the translation handle only rotates about 90 and then stops then the plug assembly is not fully unthreaded from the access fitting Return to step d and continue to unthread the plug If it rotates freely then the plug is unthreaded and you will continue rotating counterclockwise until it stops when the socket adapter carrier has reached the top of the retrieval tool f Slowly close the service valve making sure there 1s no obstruction in the valve Once fully closed bleed off pressure from the retrieval tool using either the bleed valve on the retriever or the service valve or both Verify pressure has been completely bled using the pressure gage on the retrieval tool g Remove the retriever from the service valve Once removed you can rotate the translation handle clockwise to move the plug as
39. or The nitrogen bottle be fitted with a bleed valve This is desirable to allow bleeding down the hose after back pressuring is completed 6 3 Nitrogen bottle control valve Open the control valve and allow pressure build up within the hose to 100 psi 6 BAR above the line pressure 6 4 Open the retriever bleed valve and allow the nitrogen pressure to enter the retriever Normally the pressure will come to a balance and the excess pressure will enter the operating line A back pressure or pressure flow reverse will have been accomplished In doing so debris contaminants or other obstructions within the retriever service valve plug assembly or access fitting body will be dislodged to enter the product stream flow 6 5 Close the retriever bleed valve 6 6 Close the nitrogen bottle control valve Bleed off the pressure within the hose and disconnect 1t from the retriever bleed valve emove plug assembly in the normal manner and as previously described in Section 6 7 R the pl bl tl al d ly d bed in Secti 22 SECTION 7 0 RETRIEVER amp SERVICE VALVE SPECIAL TOOLS When using the service tools described within this section it is advisable to use the shortest stroke and consequently the lightest retriever available Besides easier handling it will provide the best feel when using the special tools The following procedures assume that the service valve is installed on the access fitting b
40. pe plug are removed from the fitting and the plug 1s loosened slightly or cracked The retriever and service valve should be checked to assure smooth operation and proper assembly 2 Install the service valve onto the access fitting Insure that the valve is fully open and the bleed and bypass valves are closed 3 Install the retriever onto the service valve Insure that the bleed valve on the retriever 15 closed 4 Use the retriever to retrieve the plug assembly The general steps are as follows a Rotate the translation handle clockwise to move the socket adapter to the top of the plug b Rotate the rotation handle clockwise to thread the socket adapter into the plug assembly Slight clockwise pressure should be maintained on the translation handle to move the carrier forward as the thread engages the plug assembly but not so much pressure that the hex on the socket adapter drops over the plug assembly Thread the socket adapter into the plug assembly about 4 or 5 turns c Rotate the translation handle clockwise to drop the hex over the plug assembly The rotation handle will need to be turned slightly during this operation in order to line up the hex with the plug You will know when it is aligned and dropped onto the plug when the translation handle can advance about 90 Also the rotation handle will be difficult to turn when the hex 1s dropped over the fitting d While maintaining slight clockwise pressure on the translati
41. r one retrieval others can deposit debris in the retriever making operation difficult There are three levels of maintenance required The level of maintenance required and the frequency required will vary depending on the frequency of use process conditions anticipated length of storage and condition of the retriever Flush and Lubricate This level does not require any disassembly of the retriever It consists of repeated filling and flushing of the tool with a suitable lubricant If in a days operation because of adverse retrieval environment conditions the retriever becomes difficult to operate feels gritty and does not stroke or turn easily it should first be cleaned and lubricated without disassembly as indicated in Part 8 2 below If cleaning and lubricating without disassembly does not relieve the difficulties in the retriever operation it should be completely disassembled cleaned and lubricated as indicated in either Part 8 3 or 8 4 of this Section Disassembly and Cleaning This level requires simple disassembly of the hammer nut assembly and the head assembly This will allow removal of the translation tube rotation tube and socket adapter and carrier for cleaning and lubricating If the retriever has been in use and it is anticipated not being used again for a period longer than one day it should be completely disassembled cleaned and lubricated Overhaul and Seal Replacement This level requires an overhaul of the head a
42. requirements and environmental regulations Identify the type media its pressure and temperature Review material safety data information on the media prior to operation Insure you have all the required safety equipment for the given media Le hard hat safety glasses protective clothing safety gloves respirator spill safety equipment etc Any actions which could vary system pressure such as surges caused by opening and closing of valves and chokes should be delayed until completion of retrieval operations Insure you have enough clearance for safe operation Note wind direction prior to starting operations involving hazardous products SECTION 3 0 RETRIEVER amp SERVICE VALVE CONSTRUCTION amp OPERATION RSL 2500 retrievers feature a stainless steel outer barrel Viton o rings and graphite impregnated Teflon dynamic seals They are pressure rated to 2500 psi 172 BAR and have a maximum operating temperature of 400 F 204 C RSL 6000 retrievers feature a stainless steel outer barrel Viton o rings and graphite impregnated Teflon dynamic seals They are pressure rated to 6000 psi 414 BAR and have a maximum operating temperature of 400 F 204 C On both models a socket adapter assembly attached to the carrier assembly is used to install or retrieve the plug from the access fitting assembly The hammer nut on the outer barrel of the retriever connects directly to the outlet side of the service valves Two valve
43. rs can be done by using thread files or for more severe damage the thread die assembly part number 125112 can be used A spare access fitting body can be used to check for fit b Replace all o rings and packings If the plug assembly was previously used it is recommended that the seals be replaced Connect the corrosion monitoring or preventing device the plug assembly After initial packing contact compress the packing by tightening the device up to 1 4 turn more Securely lock into place by tightening the set screw d Index the plug assembly hex If the corrosion monitoring or preventing device requires orienting with the product flow index the plug assembly by filing a notch across the top of the hex The notch should be filed so that the device can be aligned with the product flow Clean the fitting threads if required Thread condition can be assessed by the ease of the removal procedure If repair and or cleaning appear necessary see Section 7 Retriever and Service Valve Special Tools Connect the plug assembly to socket adapter pilot Engage the plug assembly female threads to the socket adapter pilot male threads Do not bottom the plug assembly on the socket adapter pilot but allow approximately 1 4 turn back off from full engagement the o ring on the socket adapter pilot should provide the proper spacing when hand tight Align the hex on the plug assembly with the hex on the socket adapter to ensure they will
44. s are available The standard valve is rated at 3600 psi 248 BAR and the high pressure valve is rated at 6000 psi 413 BAR Both valves have a maximum operating temperature of 250 F Their selection depends on the maximum working pressure required The service valves incorporate two needle valves the first allows slow pressurizing of the retriever which reduces the torque required to open the service valve ball The second allows product bleed off through a special port either with or without the optional diverter hose assembly The valves comply with API Fire Safe Standard RPOF When the fittings are mounted at bottom of line they collect sand scale or other debris These particles can damage the threads of the access fittings as well as the working surfaces of the retriever and service valve Therefore extra care and maintenance should be given to equipment used servicing any bottom mounted fitting Special tools are available to aid in these situations See Section 7 Retriever and Service Valve Special Tools which describe the tools available to remove or flush sand scale hot tap chips or other debris from the access fitting If product and operating pressure permit lower than 2500 PSI 172 BAR the RSL 2500 retriever with its thinner stainless steel outer barrel should be considered to reduce the weight The retriever has eight main parts see figure 1 1 Outer Barrel 2 Rotation Tube 3 Translation Tube Socket Adap
45. sembly out of the front of the tool for removal 5 To install a new device into the system the following general steps are used These steps will be covered in greater detail in section 5 a Insure that the service valve is installed on the fitting and that the valve as well as the bleed and bypass valves are closed b Install the new device onto the socket adapter assembly at least 4 to 5 turns Rotate the translation counterclockwise until it stops to fully retract the new device into the retriever tool c Install the retriever onto the service valve Insure that the bleed valve on the retriever 1s closed d Slowly open the bypass valve on the service valve Verify full system pressure on the pressure gage on the retriever e Slowly open the service valve Insure the valve is open completely f Rotate the translation handle clockwise until it stops While maintaining clockwise pressure on the translation handle rotate the rotation handle clockwise to thread the plug assembly into the access fitting body Maintain clockwise pressure on the translation handle to insure that the socket adapter hex remains over the plug assembly The plug assembly requires approximately 14 turns to fully seat into the access fitting body g Rotate the translation handle counterclockwise to back the hex off of the access fitting body The translation handle should move about 90 counterclockwise Rotate the rotation handle counterclockwise a min
46. si 41 3 MPa for the model RSL 6000 retriever Note that the pressure rating for the retriever is engraved on the outer barrel of the tool Retriever Overhaul and Seal Replacement see Figure 8 If the Rotation handle or the Translation handle do not operate smoothly or you feel any grinding and or notice any pressure leaks the Head Assembly should be overhauled and the seals replaced 32 Figure 3 Disassemble the tool per section 8 3 paragraphs 1 6 Using the Drive Punch provided drive out the Roll Pin 20 from the Socket Drive 8 Remove the Socket Drive 8 from the Translation Shaft 4 Set aside the Translation Shaft Thrust Washer 7 Loosen the Set Screw holding the Drive Ring 16 and remove the Drive Ring 16 from the Translation Shaft 4 Set aside the Rotation Shaft Thrust Washer 19 All remaining items may now be separated from each other All parts will separate without use of tools however due to the close tolerances and lubrication some items may be difficult to separate Generally using the mating part in the opposite direction will provide enough force to remove the part The two seal carriers will still have the seals attached Both carriers hold the high pressure dynamic seal on the inside and a static O ring on the outside Use a small flat blade screwdriver to remove the seals and O rings using care not to damage the surface of the carrier Discard the seals Thoroughly clean a
47. ssembly If operation of the rotation or translation handles becomes difficult or feels gritty after cleaning the tool as described in paragraph 2 or there is any leakage from the head assembly then overhaul and replacement of the seals should be performed as indicated in Part 8 4 of this section Lubricant choices are many For a particular service some experimentation may be necessary Recommended lubricants are 8 1 L Motor Oil SAE 30 weight or equivalent VA Lubriplate multi purpose A lithium base grease usually the best choice for most service since it is thin and applies easily Use for service temperatures of 0 to 350 F 18 to 177 Available as COSASCO 129372 3 Synthetic lubricant A molybdenum disulfide grease containing rust and oxidation inhibitors It is recommended for use in extreme pressures and temperatures 40 to 600 F 40 to 316 C Available as COSASCO 201688 Sour Gas Service On the model RSL retriever applicable materials comply with the requirements of NACE standard MRO175 Sulfide Stress Cracking Resistant Metallic Materials for Oil Field 29 8 2 8 3 Equipment As stated this standard Materials are resistant to but not necessarily immune to sulfide stress cracking under all service conditions Thus when the retriever is used in sour environments it must be thoroughly cleaned after use to help prevent corrosion and or damage to internal materials
48. ter Carrier 5 Socket Adapter Assembly 6 Head Assembly 7 Hammer Nut Assembly 8 Bleed Valve Assembly Figure 1 0 6 HEAD ASSEMBLY 8 BLEED VALVE ASSEMBLY 1 OUTER BARREL 2 ROTATION TUBE 3 TRANSLATION TUBE 4 SOCKET ADAPTER CARRIER SOCKET ADAPTER ASSEMBLY 7 HAMMER NUT ASSEMBLY The socket adapter carrier is moved in translation and rotation by rotating the two handles on the head assembly Rotating the outermost handle clockwise moves the carrier into the access fitting or rotating it counterclockwise moves the carrier into the retriever Rotating the larger inner handle clockwise rotates the carrier in the same direction as the handle The service valve has three main parts The service valve body 2 The ball and seals 3 The bypass and bleed valve The COSASCO access fitting body and plug assembly hollow or solid form a seal However the design allows the system pressure to bypass the seal when the plug assembly is backed off one or two turns The bypass pressure enters the retriever through the service valve A normal retrieval operation consists of the following steps Each step will be covered in further detail in section 4 1 Prepare the access fitting This involves verifying the system parameters pressure temperature process fluid system surges etc The area must be checked for adequate clearances safety other personnel etc The protective cover and pi
49. the flow direction Ifthe plug assembly was installed as described sufficient room for travel to allow orienting will be available CAUTION DO NOT TURN THE PLUG ASSEMBLY HEX COUNTERCLOCKWISE TO ACHIEVE ORIENTATION Prior to installing the protective cover thoroughly grease the acme threads on the access fitting body This measure will save many hours of cleaning when the access fitting is next serviced 19 20 SECTION 6 0 RETRIEVER BACK PRESSURING Back pressuring is the pressurizing of the retriever from an external source through the retriever bleed valve This procedure may be necessary when the plug assembly will not allow line pressure to bleed past it within the access fitting body or removing fittings at high pressures with the RSL retriever Several means of back pressuring may be used a Nitrogen bottle b Hydraulic Part No 203855 or pneumatic pump An adjacent tee access fitting utilizing its line pressure The nitrogen bottle method is the procedure described The procedure assumes that the retriever and service valve are connected to the access fitting body 6 1 Connect a high pressure hose to the retriever bleed valve 6 2 Nitrogen bottle connection Connect the other end of the high pressure hose to the nitrogen bottle outlet It is recommended that a The nitrogen bottle pressure be at least 200 psi 13 BAR higher than the line pressure b The nitrogen bottle be equipped with a regulat
50. the retainer 16 Assemble the hammer nut adapter assembly 20 and retainer 16 onto the valve body 1 with the four 3 4 Allen head cap screws 19 using a 5 8 Allen wrench DO NOT tighten them securely at this stage Partially assemble the bonnet by installing the back up ring 8 and stem seal 9 in the bonnet 2 Install the thrust washer 10 and stem 8 in the bonnet 2 Position the bonnet to valve body o ring 11 in the valve body 1 stem recess Carefully position the bonnet 2 onto the valve body 1 ensuring that the thrust washer 10 is eased into position concentric with the o ring 11 Torque the four 7 16 Allen head cap screws 28 to 30 ft lb and the two 1 2 Allen head cap screws 24 retaining the bonnet 2 to the valve body 1 to 50 ft Ib Use a 5 16 and 3 8 Allen wrench respectively 38 10 11 12 Install the position stop plate 25 over the top of the stem 3 and position the valve ball handle 5 onto the square head of the stem Ensure that handle positioning points away from the hammer nut end 20 when the valve ball 12 is in the open position Tighten the 5 16 Allen head cap screw 4 retaining the handle 5 to the stem 3 by using a 1 4 Allen wrench Torque the four 3 4 Allen head cap screws 14 that were initially installed as indicated in paragraph 4 to retain the hammer nut adapter assembly 20 and retainer 10 to 130 ft lb Install the by pass or vent valves
51. tion shafts Both shafts should move with moderate resistance and smoothly with no grinding 11 Reassembly the retriever tool in accordance with section 8 to 14 36 SECTION 9 0 3600 PSI SERVICE VALVE MAINTENANCE The maintenance interval required for the service valve will be determined by the media acting upon the valve Sand grit or metal chips may damage seats causing leaks which will require seat replacement Occasional lubrication will be necessary to reduce opening torque The use of a synthetic lubricant such as Cosasco 201688 is recommended 9 1 92 Sour Gas Service On both the 3600 PSI and 6000 PSI service valves applicable materials comply with the requirements of NACE standard MRO175 Sulfide Stress Cracking Resistant Metallic Materials for Oil Field Equipment As stated in this standard Materials are resistant to but not necessarily immune to sulfide stress cracking under all service conditions Thus when the valve is used in sour environments it must be thoroughly cleaned after use to help prevent corrosion and or damage to internal materials Service Valve Disassembly Applicable to 3600 pound service valve kit P N 061001 valve P N 601000 The RBSA RBS service valve has a valve ball that is removable only from the service valve hammer nut end access fitting body connection 1 Remove the four 3 4 Allen head cap screws 19 at the hammer nut end 20 using a 5 8 Allen wrench The
52. unterclockwise to draw the plug assembly completely into the retriever tool If the translation handle stops after about Y of a turn then the plug assembly is not completely removed from the access fitting body In this case drop the hex back over the plug assembly see paragraph 14 and continue to unthread the plug assembly until it is completely withdrawn from the access fitting body Close the service valve equalizing valve and the service valve ball 14 19 20 22 23 a Close the service valve equalizing valve The service valve extension handle features a slotted end to engage the roll pin of the equalizing valve stem for easy opening and closing b Close the service valve ball using the service valve extension handle Bleed off retriever pressure The retriever 1s still fully pressurized at this stage and this pressure must be fully relieved An optional diverter hose assembly 1s recommended when bleeding off retriever pressure fluids can be collected in a container or diverted to a safe area away from the operator The hose is attached by quick connect to either the retriever bleed valve or the open port in the service valve Optional diverter hose assemblies are 124669 diverter hose assy 10 ft 3 0 m 124931 diverter hose assy 25 ft 7 6 m 124685 diverter hose assy 50 ft 15 2 m Bleed the pressure from the retriever by opening the retriever bleed valve one or two turns for gas or liquid on bottom
53. when the translation handle can advance about 90 Also the rotation handle will be difficult to turn when the hex is dropped over the fitting You may need to rotate the rotation handle in either a clockwise or counter clockwise direction while maintaining clockwise pressure on the translation handle until you feel the hex drop onto the plug assembly This is the one other operation which can be easily mastered with a few practice sessions 13 Retriever pressure balancing Although this tool does not telescope and introducing pressure into the tool does not present any unusual safety hazard it is good practice and safest to introduce pressure into the tool slowly and avoid any sudden pressure changes or surges 16 17 18 a While maintaining clockwise pressure on the translation handle to assure the hex stays firmly over the plug assembly turn the rotation handle slowly counterclockwise to unseat and begin backing off the plug assembly b Retriever pressurization will begin after 1 2 to 2 turns of the rotation handle Pressurization will be signified by one of three means gauge hearing the fluid enter the retriever or feeling the increase in friction as the seals experience pressure load When the retriever begins to pressurize stop turning the rotation handle and wait for the retriever to equalize pressure This is achieved only when the entire retriever and the operating line are at equal pressure I
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