User Manual - Rohrback Cosasco Systems
Contents
1. ann 9 Pressure Retaining Protective 5 11 5 1 Overview 5 2 Cover and Installation Re moVal allkl ck l netiesa 12 SAFETY WARNINGS 1 SAFETY WARNINGS CHAPTER 1 The COSASCO Hydraulic Access Assembly system has proven itself to be safe and reliable However when working with any high pressure system safety must be a primary consideration It is imperative that the following safety warnings are taken into important consideration before and during use of Retrieval Equipment Safety warnings in this document are to ensure precautions are taken for all procedures where there are risks involved Failure to follow these warnings could result in serious injury or worse 1 Safe operation under pressure requires 2 experienced and competent operators 2 Do not use retrieval equipment unless you have been trained and are competent in its safe operation 3 If it has been longer than 90 days since your last operation you should review the relevant Work Instruction and complete an operation on a pressurized test rig 4 Make sure you have complied with all plant safety requirements and environmental regulations 5 Identify the media its pressure and temperature Review material safety data information on the media prior to operation 6 Insure you have all the required safety equipment for the given media i e hard hat safety glasses protective c2. User Manual COSASCO is a registered trademarks of Rohrback Cosasco Systems Inc No part of this manual may be reproduced or transmitted in any form or by any means electronic or mechanical including photocopying and recording for any purpose without the express written permission of Rohrback Cosasco Systems Inc IMPORTANT INSTRUCTIONS Rohrback Cosasco Systems is committed to providing the safest and highest quality products services and training for the industries it serves We are committed to ensuring that all users of our equipment work safely and efficiently Fully anticipating the infinite variety of conditions that may be encountered in the field would be impossible but we have designed this user manual to emphasize safe working practices and as much as possible to convey the full benefit of our knowledge and collective experience in the use of the COSASCO Hydraulic Access Fittings This user manual is not meant to be a sole source of instruction and is intended only for an overview of COSASCO Hydraulic Access Fittings and installation of the carrier plug and protective cover on the Access Fitting on non pressurized lines ACOSASCO HRSL Retriever and 6000 PSI Service Valve must be used for the installation and removal of carrier plug from Access Fittings on pressurized lines Because these tools are used in a broad range of environments and applications it is important that the owner and operation personnel have been assessed ce
3. ation 2 Flanged Flanged fittings are available in several standard configurations a Model 56H 2 ANSI Ru Ring Joint b Model 57H 2 ANSI RF Raised Face A configurations of Access Fitting bodies are available in two types 1 Non Tee Type Non Tee fittings are used for all corrosion monitoring devices which do not require injection or sampling of the process fluid such as coupon holders Microcor probes hydrogen probes etc 2 Tee Type Tee fittings incorporate a 14 V2 34 or 1 NPT threaded outlet on the side of the fitting body This type of fitting is used with an injection sampling nut for product injection or process fluid sampling They are also used with sand monitoring probes old style Access Fitting bodies are available in a wide variety of materials Typically the Access Fitting body material will be chosen to be compatible with the pipe or vessel material 6 COSASCO HYDRAULIC ACCESS FITTING USER MANUAL 3 2 Attaching the Access Fitting Body COSASCO Access Fitting Bodies which have a welded end connection flarweld welding must be performed in accordance with local and plant codes Guidelines for preparing Welding Procedures are available in Cosasco manual P N 740074 Trepanning Positioning amp Welding Manual 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
4. er then tighten the set screw using a hex key For a probe such as ER screw the hollow plug nut on to the carrier plug until it contacts the primary packing ensuring that the old probe seal is not present in the plug nut and then tighten using a suitable spanner Ensuring that a probe seal is present on the shaft of the new probe screw the probe in to the hollow plug nut anticlockwise reverse thread until the probe seal makes contact with the carrier plug and tighten firmly using a suitable spanner then tighten the set screws using a hex key If inserting the plug under pressure with the use of the HRSL Retriever and 6000 PSI Service Valve refer to the Work Instruction supplied with the Retriever and or Service Valve If inserting the plug manually gently push the plug assembly into the Access Fitting body Once the carrier plug is seated tighten all four access fitting locking pins Each pin will screw in approx 3 4 turns before coming into contact with the carrier plug Once contact is achieved the pins must be tightened evenly but not excessively Note Working the locking pins opposites at all times will ensure the plug is seated correctly 10 COSASCO HYDRAULIC ACCESS FITTING USER MANUAL PRESSURE RETAINING PROTECTIVE COVERS 14 PRESSURE RETAINING PROTECTIVE COVERS CHAPTER 5 5 1 Overview Pressure Retaining and Protective Covers thread onto the external thread on the Hydraulic Access Fitting Body The Pressure Reta
5. etaining seal nuts that prevent moisture and debris from entering the locking pin cavity They also act as a second level of pressure containment for enhanced protection The COSASCO Hydraulic Access Fitting Assembly consists of four main components Access Fitting Body Hollow Solid Plug Locking Pins and Moisture Seal Nuts Pressure Retaining Protective Cover 9 Pressure Retaining Protective Cover Carrier Plug Locking Pins and Moisture Seal Nuts F lt Access Fitting Body For Access Under Pressure a COSASCO HRSL Retriever and RCS 6000 PSI Service Valve are required One HRSL Retriever and 6000 PSI Service Valve may be used to maintain a number of Access Fitting Assemblies 3 4 COSASCO HYDRAULIC ACCESS FITTING USER MANUAL HYDRAULIC ACCESS FITTING BODY 5 HYDRAULIC ACCESS FITTING BODY CHAPTER 3 3 1 Hydraulic Access Fitting Body Types The COSASCO Hydraulic Access Fitting body is available in several standard mounting configurations Flarweld ANSI Flange RJ ANSI Flange RF 1 Flarweld The model 50H Flarweld Hydraulic Access Fitting body is designed to be welded directly to the pipe or vessel The fitting incorporates a radius to match the curvature of the pipe or vessel with a maximum 1 16 weld gap It also incorporates a thick body to provide adequate branch reinforcement area to help strengthen the weld joint It is the most popular type of mounting configur
6. h the plug and is used to hold devices which require an external connection such as corrosion monitoring probes and hydrogen monitoring probes Wear Ring Seal Hollow Plug Body Wear Ring Seal lt Primary Packing Seal Hollow Plug Nut lt Bore Seal Nut Only used when no other device is attached ACCESS FITTING PLUG 9 4 2 installing the Plug Installing operating or maintaining a Rohrback Cosasco Systems high pressure HRSL retrieval tool improperly could lead to a leak serious injury or worse from a surge of pressure into the Retriever damaging the internals of the retriever Comply with all information on the product in this user manual and in COSASCO System Safety Awareness Training that apply to the product Do not allow untrained or inexperienced personnel to work with this product Use COSASCO parts and work procedures specified in this work instruction Inspect the carrier plug for any damage If there is significant damage it will be necessary to use a new carrier plug Fit a new primary packing and where necessary replace the 2 x wear rings on the plug The wear ring ends should not meet when installed on the plug Note Devices fitted to a solid plug have a reverse thread and devices fitted to a hollow plug nut have a reverse thread For a solid plug screw the coupon holder or chemical injection nut down on to the primary packing seal and tighten using a suitable spann
7. hat the information furnished will meet applicable USA including OSHA United Kingdom or any other country s health or safety standards or requirements or by implementing any of the programs that you or your company will be compliant with such rules and regulations Rohrback Cosasco Systems Inc and its affiliates assume no liability arising from the use of or reliance on the information provided in this user manual Always seek the advice of your legal medical or other advisors before using this information in this user manual NEITHER ROHRBACK COSASCO SYSTEMS INC NOR ITS INSTRUCTORS ARE RESPONSIBLE FOR THE USE BY ANY TRAINEE OR ORGANIZATION OF THIS USER MANUAL OR ANY INFORMATION CONTAINED HEREIN ANY PERSON OR ORGANIZATION UTILIZING THIS USER MANUAL FOR ANY PURPOSE DOES SOAT ITS HIS HER OWN RISK Chapter 1 Chapter 2 Chapter 3 Chapter 4 Chapter 5 Safety WarninGS cccic cscccccceccssescsendaccesessseseearccavancsieasseseuocsvascieens 1 MONG OU BOARPOSBENDEERBUELDERLDUBEEUENEUEFEEESEEEELFELEEELLFELEEEE EP 3 Hydraulic Access Fitting 5 3 1 Access Fitting Body TYPES aeaaeai iae ataie aidian 5 3 2 Attaching Table of Contents thie Access Fitting srein ea ein 6 Access Fitting PIUQ cccssseeeeeeseeeeeeessseeeeeesseeeeeseneeeeeneans 7 4 1 Solid and 4 2 Installing Hollow ection 7 the
8. ining Cover acts as a secondary process containment and includes a Bleed Valve and Pressure Gauge The Protective Covers protect the external thread and external seal area on the Access Fitting Body from damage Several configurations are available 1 P N 740106 Hydraulic Heavy Duty Cover without Hole Anon pressure retaining steel cover for use with devices that do not require routine access to the plug assembly such as coupon holders 2 P N 740107 Hydraulic Heavy Duty Cover with Hole Anon pressure retaining steel cover with an access hole on the top for use with devices that require routine access to the plug assembly such as corrosion monitoring probes 10 P N 740101 Pressure Retaining Hydraulic Cover with Bleed Valve amp Pressure Gauge A pressure retaining steel cover with an integral bleed valve and pressure gauge rated for a maximum pressure of 10 000 PSI The bleed valve must always be opened prior to removing the cover If pressure cannot be bled the cover must be left in place and the fitting repaired with the line depressurized 12 COSASCO HYDRAULIC ACCESS FITTING USER MANUAL 11 P N 740103 Pressure Retaining Hydraulic Cover with Bleed Valve Pressure Gauge and 12 NPT Center Hole for Standard Probe Adapter A pressure retaining steel cover with an integral bleed valve and pressure gauge rated for a maximum pressure of 2500 PSI This cover has a V2 NPT in the top of the cover to accom
9. lothing safety gloves respirator spill safety equipment etc 7 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 8 Ensure you have enough clearance for safe operation Note wind direction prior to starting operations involving hazardous products 9 WARNING Surface temperature may be hot Contact may cause burn 2 COSASCO HYDRAULIC ACCESS FITTING USER MANUAL 10 WARNING Do not exceed equipment specified pressure rating Over pressurization can cause equipment to fail burst posing a variety of safety hazards 11 WARNING Do not apply a load of more than 150 pounds perpendicular to the Access Fitting thread axis on any access fitting attachment to prevent breakage from bending stresses 12 WARNING Heavy Pressure Retaining Covers are available as an optional means of protecting Access Fitting external threads from damage and add an extra safety pressure layer in the event that a fitting may leak INTRODUCTION INTRODUCTION CHAPTER 2 When the hydraulic method of retrieval is preferred the COSASCO Hydraulic Access System offers several advantages over other hydraulic access fittings including a corrosion resistant locking pin system and a HRSL retrieval tool that can be used for both mechanical and hydraulic 2 system access fittings The hydraulic access fitting locking pins are protected with pressure r
10. not provided with the Access Fitting body and must be chosen to be compatible with the process fluids and conditions The suggested sequence for tightening flange bolts is shown below To provide even sealing pressure on the flange gasket the bolts should be hand tightened according to the sequence until the flange faces are in contact with the gasket Then firmly tighten the bolts in the same sequence NOTE Hot Flow of gasket material may occur under operating conditions resulting in loss of bolt pressure Bolts should be retightened after operating temperature has been reached ACCESS FITTING PLUG 7 ACCESS FITTING PLUG CHAPTER 4 4 1 Solid and Hollow Plugs The Access Fitting plug is the retrievable carrier which holds the device coupon holder probe chemical injection nut etc which may be installed into the Hydraulic Access Fitting There are two types of plugs 1 Solid Plug This plug has a solid bore and is used to hold devices which do not require external connections such as coupon holders They are always used in conjunction with devices which interface to a side tee access fitting such as injection or sampling systems or sand probes Wear Ring Seal Solid Plug Body Wear Ring Seal lt Primary Packing Seal lt Solid Plug Nut Only used when no other device is attached 8 COSASCO HYDRAULIC ACCESS FITTING USER MANUAL 2 Hollow Plug This plug has a hollow bore throug
11. odate a standard 2500 PSI pressure retaining Probe 12 P N 740105 Pressure Retaining Hydraulic Cover with Bleed Valve Pressure Gauge and Center Hole for High Pressure Probe Adapter Must use High Pressure 10 000 PSI Probe Adapter with this Cover A pressure retaining steel cover with an integral bleed valve and pressure gauge rated for a maximum pressure of 10 000 PSI This cover has a center hole in the top of the cover to accommodate a high pressure 10 000 PSI retaining Probe Adapter The bleed valve must always be opened prior to removing the cover If pressure cannot be bled the cover must be left in place and the fitting repaired with the line depressurized 5 2 Cover Installation amp Removal All hydraulic pressure retaining and heavy duty covers are supplied with an internal o ring Make certain that the o ring is fitted into the internal groove Make certain that flat area sealing surface above the external threads on the access fitting body is 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 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 To remove the cover simply unthread the c
12. over from the fitting using a spanner wrench to loosen the cover if required Rohrback Cosasco Systems Inc 11841 E Smith Avenue Santa Fe Springs CA 90670 Tel 562 949 0123 800 635 6898 Fax 562 949 3065 E mail sales cosasco com www cosasco com ROHRBACK COSASCO SYSTEMS
13. rtified and deemed competent in all safety work management and additional risk assessment requirements in the application of this procedure Installing operating or maintaining a Rohrback Cosasco Systems high pressure HRSL retrieval tool improperly could lead to a leak serious injury or worse from a surge of pressure into the Retriever damaging the internals of the retriever Comply with all information on the product in this user manual and in COSASCO System A Safety Awareness Training that apply to the product Do not allow untrained or inexperienced personnel to work with this product Use COSASCO parts and work procedures specified in this work instruction BE SURE ALL PERSONNEL READ AND FOLLOW THE INSTRUCTIONS IN THIS USER MANUAL AND ALL PRODUCT WARNINGS Product Owners Purchasers 1 Use the correct product for the environment and pressures present If you are unsure discuss your needs with your RCS representative 2 Inform educate and train all personnel in the proper installation operation and maintenance of this product 3 To ensure proper performance only competent field experienced and trained personnel should install operate repair and maintain this product 4 Save this user manual for future reference Product Operation Personnel Read and understand all instructions and operating procedures for this product Follow all warnings cautions and notices marked on and supplied with this produc
14. t Follow all instructions during the installation operation and maintenance of this product To prevent personal injury ensure that all components are in place prior to and during operation of the product 5 If you do not understand an instruction or do not feel comfortable following the instructions contact an RCS service technician for clarification or assistance 6 If this user manual is not the correct user manual for your RCS product contact RCS at 1 562 949 0123 and RCS will provide you with the requested manual 7 Use only replacement parts specified by RCS Unauthorized parts and procedures can affect this product s performance safety and invalidate the warranty Look a like substitutions may result in improper operation and may result in serious injury or death 8 Save this user manual for future reference POU Hrn NOTICE Information provided in COSASCO Hydraulic Access Fitting User Manual should not be considered as all encompassing or suitable for all situations conditions or environments Each individual and the organization he she represents is responsible for implementing training and its his her own safety injury illness prevention program in connection with this user manual and should consult with their respective legal medical or other advisors as to the suitability of using the information in connection with this user manual Application of information furnished by this user manual does not guarantee t
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