Professional Documents
Culture Documents
Hydraulic Retrieval Tool Manual
Hydraulic Retrieval Tool Manual
Service Valve
2SHUDWLRQ 0DLQWHQDQFH0DQXDO
5HY2
0HWDO6DPSOHV
A Division of Alabama Specialty Products, Inc.
0HWDO6DPSOHV5G0XQIRUG$/3KRQH)D[
(PDLOPVF#DOVSLFRP,QWHUQHWZZZPHWDOVDPSOHVFRP
,QGH[
&+$37(5,QWURGXFWLRQ
6FRSHRI0DQXDO
&+$37(5±0DLQ'DWD
*XDUDQWHH5HVWULFWLRQ
7RRO'DWD+\GUDXOLF5HWULHYHU
+\GUDXOLF5HWULHYDO7RROVIRU6LQJOH6LQJOH%DOO'RXEOH'RXEOH%DOO
,VRODWLRQ6HUYLFH9DOYH
5HVWULFWLRQRQXVH
&+$37(5±7HFKQLFDO'HVFULSWLRQ
'RXEOH$FWLQJ+\GUDXOLF5HWULHYHU
&+$37(5±2SHUDWLRQ,QVWUXFWLRQ
,PSRUWDQW6DIHW\,QIRUPDWLRQ
2SHUDWRUV4XDOLILFDWLRQ
3UHSDUDWLRQV
5HWULHYDOIURPDSUHVVXUL]HGOLQH
,QVWDOODWLRQRID0RQLWRULQJ'HYLFHLQWRD3UHVVXUL]HG3LSH
7UDLQLQJSURJUDPIRU2SHUDWRUV
&+$37(50DLQWHQDQFH
*HQHUDO
,QWURGXFWLRQ
0DLQWHQDQFHLQVWUXFWLRQV
5RXWLQH,QVSHFWLRQVEHIRUHXVH
3HULRGLF0DLQWHQDQFH
0DLQWHQDQFHDIWHUXVH
6WRULQJSUHVHUYDWLRQDQGPDLQWHQDQFHRISUHVHUYDWLRQ
&+$37(5±6SDUH3DUWV/LVW
'RXEOH$FWLQJ+\GUDXOLF5HWULHYHU
6HUYLFH9DOYH
6LQJOH,VRODWLRQ9DOYH
'RXEOH,VRODWLRQ9DOYH
3XPSV
0DQXDO+\GUDXOLF3XPS
$LU+\GUDXOLF3XPS
&+$37(5'UDZLQJV
'RXEOH$FWLQJ+\GUDXOLF5HWULHYHU
*HQHUDO$UUDQJHPHQW'UDZLQJZLWK3DUW/LVW
'RXEOH,VRODWLRQ6HUYLFH9DOYH
*HQHUDO$UUDQJHPHQW'UDZLQJZLWK3DUW/LVW
&+$37(56HTXHQFHRI2SHUDWLRQV
&+$37(5,QWURGXFWLRQ
6FRSHRI0DQXDO
7KLV PDQXDO VSHFLILHV WKH SURSHU XVDJH VXFK DV LQVWDOODWLRQ DQG RSHUDWLRQ DQG
PDLQWHQDQFH RI WKH 0HWDO 6DPSOHV K\GUDXOLF UHWULHYDO V\VWHP ,W DOVR FRYHUV FHUWDLQ
VDIHW\UHTXLUHPHQWVDQGJHQHUDOEUHDNGRZQRIVXEFRPSRQHQWV
&+$37(5±0DLQ'DWD
*XDUDQWHH5HVWULFWLRQ
9LVXDOO\ LQVSHFW DOO FRPSRQHQWV IRU VKLSSLQJ GDPDJH ,I VKLSSLQJ GDPDJH LV IRXQG
QRWLI\ FDUULHU DW RQFH6KLSSLQJ GDPDJH LV QRW FRYHUHG E\ WKH ZDUUDQW\7KH FDUULHU LV
UHVSRQVLEOHIRUDOOUHSDLUDQGUHSODFHPHQWFRVWVUHVXOWLQJIURPVKLSPHQWGDPDJH
:$51,1*
5HDGDQGIROORZDOOLQVWUXFWLRQVZDUQLQJVDQGFDXWLRQVWRDYRLGSHUVRQDOLQMXU\RU
SURSHUW\GDPDJHGXULQJV\VWHPRSHUDWLRQ0(7$/6$03/(6LVQRWUHVSRQVLEOH
IRUGDPDJHRULQMXU\UHVXOWLQJIURPXQVDIHXVHRISURGXFWODFNRIPDLQWHQDQFH
LQFRUUHFWLQVWDOODWLRQRIHTXLSPHQWDQGRUV\VWHPRSHUDWLRQ&RQWDFW0(7$/
6$03/(6LQFDVHRIGRXEWDERXWDQ\DSSOLFDWLRQVDQGVDIHW\SUHFDXWLRQV
GHVFULEHGKHUHLQ
7RRO'DWD+\GUDXOLF5HWULHYHU
7KH'RXEOH$FWLQJ+\GUDXOLFFDQEHXVHGIRUinstalling/reSODFLQJ corrosion
monitoringequipment such as FRUURVLRQSUREHVXQGHUIXOOOLQHSUHVVXUHZLWKRXW
VKXWWLQJGRZQDQGGHSUHVVXUL]LQJWKHSLSHV\VWHP
7KH'RXEOH$FWLQJ+\GUDXOLF5HWULHYHULVVXSSOLHGZLWKD6HUYLFH9DOYHZLWKVLQJOH
LVRODWLRQRQHEDOODVVWDQGDUG)RUPRUHVDIHW\D6HUYLFH9DOYHZLWKGRXEOH
LVRODWLRQWZRVHSDUDWHEDOOVLVDOVRDYDLODEOH127('XHWRWKHLQFUHDVHGKHLJKW
RIWKH'RXEOH,VRODWLRQ6HUYLFH9DOYHDVSHFLDO'RXEOH$FWLQJ+\GUDXOLF
5HWULHYHULVUHTXLUHGIRUXVHZLWKWKLVYDOYH
7KH+\GUDXOLF5HWULHYHUFDQEHRSHUDWHGHLWKHUZLWKDPDQXDOK\GUDXOLFSXPSRUDQ
DLUGULYHQK\GUDXOLFSXPS:KHQXVLQJDQDLUGULYHQSXPSPDNHVXUHWKDWWKH
SXPSLVFRQQHFWHGWRDQDLUVXSSO\ZLWKRSHUDWLRQDOSUHVVXUHEHWZHHQSVL
EDUDQGDPLQLPXPDLUIORZRIJDOORQVPLQOPLQ
2SHUDWingParameters
0D[ZRUNLQJSUHVVXUH SVLEDU
0D[ZRUNLQJWHPSHUDWXUH )&
+\GUDXOLFWHVWSUHVVXUH SVLEDU
+\GUDXOLF5HWULHYDO7RROVIRU6LQJOH6LQJOH%DOODQG'RXEOH'RXEOH%DOO,VRODWLRQ
6HUYLFH9DOYH
7KHIROORZLQJ'RXEOH$FWLQJ+\GUDXOLF5HWULHYDO7RRO.LWVDUHIRUH[FOXVLYHXVHZLWK6LQJOH
,VRODWLRQ6HUYLFH9DOYH
7KHIROORZLQJ'RXEOH$FWLQJ+\GUDXOLF5HWULHYDO7RRO.LWVDUHIRUH[FOXVLYHXVHZLWK
'RXEOH,VRODWLRQ6HUYLFH9DOYH
NOTE!
,IWKH'RXEOH$FWLQJ+\GUDXOLF5HWULHYHULVXVHGZLWKVWDQGDUGPHFKDQLFDOILWWLQJVZLWK
D+\GUDXOLF$GDSWHUSURGXFHGE\0HWDO6DPSOHVWKHPD[SUREHKROGHUOHQJWKLV
UHGXFHGE\´PP
7KH5HWULHYHU.LWLVGHOLYHUHGZLWKD0DQXDO3XPS$Q$LU3XPSLVDYDLODEOHRQ
UHTXHVW
7KH6LQJOH,VRODWLRQ6HUYLFH9DOYHVPXVWEHRQO\XVHGZLWKD'RXEOH$FWLQJ
+\GUDXOLF5HWULHYDO7RROVSUHSDUHGIRUWKLVW\SHRI9DOYH31+$XSWR
+$
7KH'RXEOH,VRODWLRQ6HUYLFH9DOYHVPXVWEHRQO\XVHGZLWKD'RXEOH$FWLQJ
+\GUDXOLF5HWULHYDO7RROVSUHSDUHGIRUWKLVW\SHRI9DOYH31+$XSWR
+$
5HVWULFWLRQRQXVH
7KHPD[LPXPOLPLWVIRUSUHVVXUHDQGWHPSHUDWXUHVSHFLILHGLQVHFWLRQPXVW
EHREVHUYHG
7KHRZQHURIWKHSLSHV\VWHPZKHUHWKHUHWULHYHULVWREHXVHGVKRXOGDOVRLQ
FRRSHUDWLRQZLWKWUDLQHGUHWULHYHURSHUDWRUVHYDOXDWHWKHVDIHW\LVVXHVRQWKHVSHFLILF
ORFDWLRQVZKHUHWKHUHWULHYDOWRROLVWREHXVHG7KHWRWDOSURFHVVIURPVWDUWWRILQLVK
PXVWEHHYDOXDWHGEXWHVSHFLDOO\WKHSRWHQWLDOKD]DUGVFDXVHGE\WKHJDVOLTXLGIORZLQJ
LQVLGHWKHSLSHOLQHVPXVWEHFRQVLGHUHGZLWKVSHFLDODWWHQWLRQRQWKHIROORZLQJ
FDQWKHPHGLDLQWKHSLSHFDXVHGDPDJHWRWKHVHDOV[VWDQGDUG2ULQJPDWHULDOLV
FKM (Viton]LQWKH5HWULHYHUDQG6HUYLFH9DOYH"
GRHVWKHPHGLDLQWKHSLSHUHSUHVHQWDKD]DUGWRWKHRSHUDWRUVLIWKH\FRPHLQWR
FRQWDFWZLWKLW"
,IDQ\RIWKHDERYHGHVFULEHGLVVXHVRURWKHUVWKDWPLJKWKDYHEHHQLGHQWLILHGGXULQJWKH
HYDOXDWLRQDUHFRQVLGHUHGWRUHSUHVHQWDKD]DUGZKLFKFDQQRWEHFRPSHQVDWHG
SURSHUO\IRUE\VDIHW\SUHFDXWLRQVWKHQWKHUHWULHYHURSHUDWLRQVKRXOGQRWEHSHUIRUPHG
XQGHUIXOOOLQHSUHVVXUH
&+$37(5±7HFKQLFDO'HVFULSWLRQ
'RXEOH$FWLQJ+\GUDXOLF5HWULHYHU
(TXLSPHQWIRULQWHUQDOFRUURVLRQPRQLWRULQJsuch as FRUURVLRQSUREHVZHLJKWORVV
FRXSRQVDQGELR-SUREHV DUHQRUPDOO\LQVWDOOHGLQDFFHVVILWWLQJV which are in turn LQVWDOOHG
RQWKHSLSHYHVVHO$VSHFLDOYHUVLRQRIWKHDFFHVVILWWLQJV7W\SHILWWLQJVFDQDOVREH
XVHGIRULQVWDOODWLRQRIHTXLSPHQWIRULQMHFWLRQRIFKHPLFDOVRUVDPSOLQJRIWKHFRQWHQWVLQ
WKHSLSH/vessel
:LWKWKH'RXEOH$FWLQJ+\GUDXOLF5HWULHYHUHTXLSPHQWFDQEHLQVWDOOHGLQWRRUUHWULHYHG
IURPDFFHVVILWWLQJVZKLOHWKHSLSHV\VWHPLVpressurized7KHVWDQGDUG'RXEOH$FWLQJ
+\GUDXOLF5HWULHYHUKDVDSUHVVXUHUDWLQJRISVLEDU and should not be used in
systems exceeding this pressure
7KH'RXEOH$FWLQJ+\GUDXOLF5HWULHYHULVGHVLJQHGWREHXVHGRQO\RQ+\GUDXOLF$FFHVV
)LWWLQJV+RZHYHULWLVDOVRSRVVLEOHWRXVHWKLVWRRORQWUDGLWLRQDOPHFKDQLFDO
$FFHVV)LWWLQJVZLWK$&0(WKUHDGVLIWKHILWWLQJKDVEHHQHTXLSSHGZLWKD
+\GUDXOLF$FFHVV)LWWLQJ$GDSWHU7KH+\GUDXOLF$FFHVV)LWWLQJV$FFHVV)LWWLQJ
$GDSWHUVGRQRWKDYHLQWHUQDOWKUHDGV,QVWHDGWKHUHWULHYDEOHSDUWVDUHNHSWLQ
SRVLWLRQE\XVHRIORFNLQJSLQVDQGKHDY\GXW\FRYHUV
7KH'RXEOH$FWLQJ+\GUDXOLF5HWULHYHULVGHVLJQHGWREHOLJKWZHLJKWDQGFRPSDFWLQ
VL]HDQGWKLVPDNHVLWVDIHUDQGHDVLHUWRRSHUDWHDQGFDQDOVRPDNHLWSRVVLEOHWR
PRQLWRUORFDWLRQVZKLFKRWKHUZLVHZRXOGEHLQDFFHVVLEOHGXHWRWKHVL]HRIWUDGLWLRQDO
PHFKDQLFDOUHWULHYDOWRROV7KHPDLQFRPSRQHQWVRIWKHUHWULHYDOWRROLVPDGHLQ
VWDLQOHVVVWHHOZKLFKPDNHVLWHDV\WRPDLQWDLQDQGVKRXOGHQVXUHDORQJVHUYLFHOLIH
7KH'RXEOH$FWLQJ+\GUDXOLF5HWULHYHULVRSHUDWHGE\HLWKHUDPDQXDOK\GUDXOLFSXPS
RUDQDLUGULYHQK\GUDXOLFSXPS:KHQWKH+\GUDXOLF5HWULHYHULVXVHGRQDSUHVVXUL]HG
V\VWHPWKHSLSHOLQHSUHVVXUHDORQHZLOOQRUPDOO\SURYLGHVXIILFLHQWIRUFHIRUUHWULHYDORI
WKHPRQLWRULQJHTXLSPHQWIURPWKHDFFHVVILWWLQJDQGLQWRWKHUHWULHYHU:KHQPRQLWRULQJ
HTXLSPHQWLVWREHLQVWDOOHGWKHK\GUDXOLFSXPSLVXVHGWRFUHDWHDKLJKHUSUHVVXUH
LQVLGHWKHUHWULHYHUWKDQLQWKHSLSHOLQHWKHUHE\SXVKLQJWKHPRQLWRULQJHTXLSPHQWLQWR
WKHDFFHVVILWWLQJ
&+$37(52SHUDWLRQ,QVWUXFWLRQ
,PSRUWDQW6DIHW\,QIRUPDWLRQ
7KLV0DQXDOKDVEHHQSUHSDUHGWRSURYLGHWHFKQLFDOLQIRUPDWLRQRQWKHRSHUDWLRQRI
WKH0HWDO6DPSOHV'RXEOH$FWLQJ+\GUDXOLF5HWULHYHUDQGLVQRWLQWHQGHGWRSURYLGH
WKHcustomerRUXVHUZLWKLQIRUPDWLRQRQWKHSURSHUUHPRYDORISUREHVLQDSUHVVXUL]HG
V\VWHP7KHSURFHGXUHVIRUSUREHUHPRYDOLQWKLVPDQXDODUHIRULOOXVWUDWLYH
SXUSRVHVRQO\
6SHFLILFUHPRYDOSURFHGXUHVPXVWEHGHYHORSHGE\WKHWRRORZQHURURSHUDWRUIRUHDFK
DSSOLFDWLRQ$VDPLQLPXPWKHVHSURFHGXUHVPXVWDGGUHVVWKHVDIHW\RIWKHWRRO
RSHUDWRUDQGWKHWHFKQLFDOHIIHFWRQWKHRSHUDWLQJV\VWHP,WLVDOVRQHFHVVDU\WKDWWKH
$SSURYHG3UREH5HPRYDO3URFHGXUHVDUHFRPSDUHGZLWKWKHLOOXVWUDWLYHH[DPSOHVXVHG
LQWKLV+\GUDXOLF5HWULHYHU2SHUDWLRQ0DQXDOWRLQVXUHWKHUHDUHQRFRQIOLFWVEHWZHHQWKH
H[DPSOHVDQGWKH$SSURYHG3UREH5HPRYDO3URFHGXUHV
Only useWRROVPDGHRIPDWHULDOVWKDWZLOOQRWSURGXFHVSDUNVZKHQXVHGVXFK
DVWRROVZLWKSODVWLFRUEUDVVVXUIDFHV
2SHUDWRUV4XDOLILFDWLRQ
2SHUDWLRQRIDUHWULHYDOWRRORQDSUHVVXUL]HGV\VWHPFDQEHYHU\GDQJHURXVDQGPXVW
RQO\EHDWWHPSWHGE\SURSHUO\WUDLQHGSHUVRQQHOVHHVHFWLRQXVLQJSURFHGXUHV
DSSURYHGE\WKHRZQHUVRIWKHRSHUDWLQJV\VWHP
,WLVYHU\LPSRUWDQWWKRXJKWKDWWKHK\GUDXOLFUHWULHYHUVKRXOGRQO\EHRSHUDWHGE\SHRSOH
ZKRIXOO\XQGHUVWDQGKRZLWZRUNVDQGDUHWUDLQHGLQLWVXVH7KHUHIRUHLWLVQRW
HQRXJKMXVWWRUHDGWKLVPDQXDO2SHUDWRUVVKRXOGEHIRUHZRUNLQJRQDQ\OLYHSLSH
V\VWHPEHVXIILFLHQWO\WUDLQHGE\TXDOLILHGLQVWUXFWRUV
2SHUDWRUVVKRXOGDOVREHIDPLOLDUZLWKWKHGLIIHUHQWFRPSRQHQWVWKDWDUHXVHGZLWKWKH
K\GUDXOLFDFFHVVILWWLQJVHJ+ROORZDQG6ROLG3OXJV/RFNLQJ3LQV+\GUDXOLF&RYHUV
DQGWKHGLIIHUHQWW\SHVRIVHDOVXVHGRQWKHVHSDUWV
3UHSDUDWLRQV
7KHSURFHGXUHLQVHFWLRQGHVFULEHVVWHSE\VWHSKRZWRRSHUDWHWKH0HWDO6DPSOHV
'RXEOH$FWLQJ+\GUDXOLF5HWULHYHULQRUGHUWRSHUIRUPWKHUHWULHYDORIDPRQLWRULQJGHYLFH
HJDFRUURVLRQSUREHLQVWDOOHGRQDSUHVVXUL]HGSLSHOLQHDQGVXEVHTXHQWUH-LQVWDOODWLRQ
RIWKHPRQLWRULQJGHYLFH
7KH SURFHGXUH FRYHUV XVH RI WKH 'RXEOH $FWLQJ +\GUDXOLF 5HWULHYHU ZLWK ERWK WKH
VWDQGDUG 6HUYLFH 9DOYH DQG WKH 'RXEOH ,VRODWLRQ 6HUYLFH 9DOYH It will be specified
throughout the procedure whereWKHUHDUHGLIIHUHQFHVLQWKHRSHUDWLRQRIWKHWZRYDOYH
W\SHV
%HIRUHWKHUHWULHYHULVXVHGLWPXVWEHFKHFNHGWRLQVXUHWKDWDOOSDUWVDUHLQJRRG
RSHUDWLQJFRQGLWLRQ6HHVHFWLRQ5RXWLQHLQVSHFWLRQEHIRUHXVH
%HIRUHWKHDLUSXPSLVXVHGSOHDVHUHDGWKHLQVWUXFWLRQVKHHWWKDWLVGHOLYHUHGZLWKWKH
SXPS
%HIRUHZRUNFRPPHQFHVRQDVSHFLILFORFDWLRQit PXVWEHFODULILHGZLWKWKHRSHUDWRUV
UHVSRQVLEOHIRUWKHDUHDSLSHV\VWHPZKHUHWKHILWWLQJLVLQVWDOOHG
8VHRIWKH+\GUDXOLF5HWULHYHULQYROYHVEOHHGLQJRISUHVVXUL]HGIOXLGJDVIURPWKHSLSH
V\VWHP,IWKHSLSHV\VWHPFRQWDLQVK\GURFDUERQVEOHHGLQJRIOLTXLGJDVPLJKWWULJJHU
JDVGHWHFWRUVKHQFHVXFKRSHUDWLRQVPXVWDOZD\VEHFODULILHGZLWKWKHRSHUDWRUVEHIRUH
WKHMREVWDUWV7KHIROORZLQJVDIHW\SUHFDXWLRQVVKRXOGDSSO\
x 7KHRSHUDWRUVFRQWUROURRPPXVWEHWROGZKHQWKHZRUNVWDUWVDQGVWRSVDWHDFK
ORFDWLRQ
x 7KHRSHUDWRUVFRQWUROURRPDUHQRWLILHGEHIRUHEOHHGLQJRIRLOJDVVRWKH\FDQE\
SDVVDQ\JDVGHWHFWRUVDQGVWRSKRWZRUNQHDUE\GXULQJWKHEOHHGLQJ
5HWULHYDOIURPDSUHVVXUL]HGOLQH
1. 0DNHVXUHWKDWWKHUHLVHQRXJKVSDFHDYDLODEOHWRXVHWKHUHWULHYHU$OVRPDNHVXUH
WKDW WKH VL]H RI WKH K\GUDXOLF UHWULHYHU LV VXIILFLHQW IRU WKH DFWXDO SUREH OHQJWK DW WKH
VHOHFWHGORFDWLRQ6HHWDEOHVLQVHFWLRQ
2. &RQILUPWKHSLSHOLQHSUHVVXUHDQGZKHWKHUYDULDWLRQVLQSUHVVXUHFDQEHH[SHFWHG
GXULQJWKHSHULRGZKHQWKHK\GUDXOLFUHWULHYHULVWREHRSHUDWHG
3. &KHFNWKHK\GUDXOLFDFFHVVILWWLQJLQFOXGLQJ
1. &KHFNWKDWWKHFRYHULVVXIILFLHQWO\WLJKWHQHG
2. 8QVFUHZWKHORFNLQJSLQVIRULQVSHFWLRQRQHDWDWLPH
3. &KHFNWKH2ULQJVIRUFXWVDQGZHDUDQGUHSODFHWKHPLIQHFHVVDU\
4. ,QVSHFWDQG,LIQHFHVVDU\,FOHDQWKHKROHLQWKHDFFHVVILWWLQJparticularlyWKH
VXUIDFHagainst which WKH2ULQJV sealILJ
4. 0DNHVXUHWKHORFNLQJSLQVDUHVXIILFLHQWO\WLJKWHQHGDIWHULQVSHFWLRQ
5. 5HPRYHWKHSLSHSOXJRU,LIDFRQWLQXRXVPRQLWRULQJFDEOHLVFRQQHFWHGdisconnect
and removeWKH FDEOH
Locking Pin
O-rings
Cover
Pipe Plug
Fig. 3
6. 5HPRYHWKHSURWHFWLYHFRYHU&KHFNIRUOHDNVDURXQGWKHSOXJDQGDURXQGWKHORFNLQJ
SLQV,IOHDNVDUHGLVFRYHUHGWKHQSXWWKHFRYHUEDFNRQDQGperformRQFH
PRUHILJ,IWKHOHDNVFDQQRWEHVWRSSHGWKHQSXWWKHFRYHUEDFNRQDQGWLJKWHQ
LW /HDYHWKHDFFHVVILWWLQJXQWLODPRUHWKRURXJKLQVSHFWLRQFDQEHSHUIRUPHG
GXULQJ WKHQH[WVKXWGRZQRIWKHV\VWHP
7. &KHFNH[WHUQDOWKUHDGVRQDFFHVVILWWLQJ&OHDQDQGOXEULFDWHLIQHFHVVDU\
Check Around Plug
and Pins for Leaks
Fig. 4
&KHFNDQGLQVSHFWWKH2ULQJRQWKHERWWRPRI6HUYLFH9DOYHILJ
0RXQWWKHVHUYLFHYDOYHRQWKHDFFHVVILWWLQJ7LJKWHQLWWRWKHILWWLQJZLWKWKHSODVWLF
KDPPHU
Check O-Ring
Fig. 5
10. &RQQHFWWKHKRVHVIURPWKHSXPSWRWKHUHWULHYHU%HIRUHXVLQJWKHSXPSREVHUYHWKHVHWWLQJVRI
WKHIORZGLUHFWLRQYDOYH5(75,(9(DQG,167$//ILJ
11. (QVXUHWKDWWKH bleedYDOYHLQWKHUHWULHYHUKHDGKHDGYDOYHLVRSHQWXUQVLVVXIILFLHQW
)RU PDQXDOSXPSVDOVRFKHFNWKDWWKHUHWXUQYDOYHRQWKHSXPSLVFORVHG6HWWKH
KDQGDLU-SXPSWR,167$//DQGSXPSXQWLOWKHFRQQHFWLQJURGLVIXOO\H[WHQGHG&RQWLQXH
WR SXPSXQWLOWKHSUHVVXUHLQVLGHWKHUHWULHYHULVDPLQLPXPRISVLEDUZDWFKWKH
SUHVVXUHJDXJHRQWKHSXPS7KHQFORVHWKHKHDG (bleed)YDOYHDQGGLVFRQQHFWWKHKRVHV
ILJ
Connecting Rod Flow Direction Valve
Installation
Direction
Return Valve
Fig. 6
+ROGWKHUHWULHYHUVRWKHFRQQHFWLQJURGIDFHVWKHVHUYLFHYDOYH3XWWKHFRQQHFWLQJURG
LQWRWKHVHUYLFHYDOYHDQGPDWHWKHWKUHDGVRQWKHURGDQGWKHSOXJWRJHWKHU6FUHZWKH
URGLQWRWKHSOXJE\URWDWLQJWKHUHWULHYHU6FUHZXQWLOWKHURWDWLRQVXGGHQO\VWRSV'RQRW
WLJKWHQILJ
&RQQHFWDJDLQWKHKRVHVIURPWKHSXPSDQGVHWWKHSXPSWR5(75,(9(2SHQ
WKHKHDGYDOYHDQGSXPSVWURNHVRQWKHKDQGDLUSXPS7KLVZLOOSXOOWKH
UHWULHYHUWRZDUGVWKHHQGIDFHRIWKHVHUYLFHYDOYH
&RQQHFWWKHKDPPHUQXWWRWKHVHUYLFHYDOYHDQGVFUHZXQWLOLWVWRSV7KHQWLJKWHQ
WKHKDPPHUQXWE\XVHRIWKHSODVWLFKDPPHUILJ
&KHFNWKDWWKHEOHHGRIIYDOYHRQWKHUHWULHYHULVFORVHG
Hammer Nut
Bleed Off Valve
By-Pass Valve
Service Valve
Retriever Rotation
Direction for Rod and
Plug Engagement
Fig. 7
16. 6HWWKHSXPSWR,167$//DQGSXPSXQWLOWKHSUHVVXUHLQWKHUHWULHYHULVDWOHDVW
SVLEDUKLJKHUWKDQWKHSUHVVXUHLQVLGHWKHSLSHOLQH,ILWLVGLIILFXOWWR
GHWHUPLQHWKHH[DFWSLSHOLQHSUHVVXUHWKHSUHVVXUHVKRXOGEHLQFUHDVHGWRDQHYHQ
KLJKHUOHYHO±SVLEDUDERYHH[SHFWHGSUHVVXUHLQWKHSLSHOLQH
Fig. 8
&KHFNWKDWWKHVHUYLFHYDOYHLVIXOO\RSHQHG2QWKHGRXEOHLVRODWLRQVHUYLFHYDOYHERWK
EDOOVPXVWEHIXOO\RSHQHG
0DNHVXUHWKDWWKHEOHHGYDOYHRQWKHUHWULHYHULVFORVHG
)RUKDQGSXPS6HWWKHSXPSWR5(75,(9(7KHQUHOHDVHWKHF\OLQGHUSUHVVXUHE\
SXPSLQJRQHVWURNHRQWKHSXPS
)RUDLUSXPS0RYHWKHKDQGOHTXLFNO\IURP,167$//WR5(75,(9(DQGDYRLG
VWRSSLQJLQWKHFHQWHUSRVLWLRQ+DQGOHLQFHQWHUSRVLWLRQZLOODOORZDTXLFNHUWKDQ
GHVLUHGUHWULHYDORIWKHSOXJSUREH
In regards toWKHSUHVVXUHLQWKHOLQHWRIXOO\UHWULHYHWKHSOXJSUREHXVHWKHKDQGDLU-
SXPSDQGNHHSSXPSLQJXQWLOWKHSUHVVXUHJDXJHRQWKHSXPSVKRZVWKDWSUHVVXUHLV
VWDUWLQJWREXLOGXSLQVLGHWKHUHWULHYHU1RUPDOO\VWURNHVGHSHQGLQJRQUHWULHYHU
VL]H7KLVLQGLFDWHVWKDWWKHSUREHLVIXOO\UHWULHYHG&KHFNIRUOHDNVDURXQGWKHORFNLQJ
SLQV,IOHDNVGRRFFXUWKHSUREHPXVWEHUHLQVWDOOHGVHHVWHSLQWKHLQVWDOODWLRQ
SURFHGXUHRIVHFWLRQ5HLQVWDOOFRYHUDQGUHFKHFNWKH2ULQJVRQWKHORFNLQJSLQV
,03257$17:KHQWKHSXPSLVLQ5(75,(9(SRVLWLRQWKHSUHVVXUHVKRXOG
QHYHUH[FHHGSVLEDUVHHJDXJHRQSXPSThe reason for thisLV:
should WKHSUREHunexpectedlybe SUHYHQWHGIURPPRYLQJRXWRIWKHILWWLQJ
DWWHPSWLQJWRUHWULHYHLWDWDKLJKHUSUHVVXUHPLJKWFDXVHGDPDJHVWRWKHSOXJRUWR
WKHUHWULHYHU itself,IWKHSOXJSUREHFDQQRWEHUHWULHYHGDWSVLEDULW
VKRXOGEHOHIWLQVLGHWKHILWWLQJXQWLOWKHQH[Wsystem VKXWGRZQ
20. &ORVHWKHVHUYLFHYDOYH,IDGRXEOHLVRODWLRQYDOYHLVXVHGDWWKLVVWDJHFORVHRQO\WKH
ORZHUEDOOFORVHVWWRWKHDFFHVVILWWLQJ8VHRIIRUFHVKould notQRUPDOO\EHUHTXLUHGto
FORVeWKHYDOYH,IWKHYDOYHFDQQRWEHFORVHGLWLVPRVWOLNHO\GXHWRRQHRIWKHIROORZLQJ
FDXVHV
7KHUHDUHODUJHDPRXQWVRIVDQGGHEULVLQVLGHWKHYDOYHKDPSHULQJWKHURWDWLRQRIWKH
EDOO
7KHSUREHLVQRWIXOO\UHWULHYHG
7KHSUREHLVIXOO\UHWULHYHGEXWWKHSUREHOHQJWKH[FHHGVWKHFDSDFLW\RIWKHUHWULHYHU
7RPDNHVXUHWKDWWKHSUREHLVIXOO\UHWULHYHGSXPSVRPHDGGLWLRQDOVWURNHVRQWKH
SXPSDQGFKHFNWKDWWKHSUHVVXUHLQVLGHWKHUHWULHYHULQFUHDVHVIRUHDFKVWURNHDQG
VWDELOL]HVDWWKHKLJKHUOHYHO,IQHFHVVDU\NHHSSXPSLQJXQWLOVXFKVWDELOL]DWLRQLV
DFKLHYHG
,I WKH YDOYH VWLOO FDQQRW EH FORVHG WKH SUREH PXVW EH reinstalled VHH LQVWDOODWLRQ
SURFHGXUHVHFWLRQVWHSs through DQGWKHYDOYHLQVSHFWHG to GHWHUPLQH
WKHcauseof the SUREOHP
22. ,03257$177KLVVHFWLRQFRQWDLQVLQIRUPDWLRQDERXWKRZWREOHHGRIIWKHSUHVVXUH
LQVLGHWKHUHWULHYHUDIWHUWKHSOXJKDVEHHQUHWULHYHGDQGWKHVHUYLFHYDOYHFORVHG
3OHDVHUHDGWKLVVHFWLRQFDUHIXOO\
%HIRUHWKHUHWULHYDORSHUDWLRQVVWDUWVLWVKRXOGEHDJUHHGXSRQZLWKWKHRSHUDWRUVRUWKH
FRQWUROURRPZKDWVDIHW\SUHFDXWLRQVVKRXOGDSSO\IRUEOHHGLQJRIIWKHPHGLDLQWKH
UHWULHYHUVHHDOVRVHFWLRQ3UHSDUDWLRQV)ROORZWKHVDIHW\SUHFDXWLRQVWKDWKDYH
EHHQDJUHHGZLWKWKHRSHUDWRUV
:LWKWKHVHUYLFHYDOYHFORVHGWKHSUHVVXUHLQVLGHWKHUHWULHYHUPXVWEHUHOHDVHG8VH
WKHEOHHGRIIYDOYHRQWKHF\OLQGHUILJ7RGRWKLVLQDFRQWUROODEOHPDQQHUDKRVH
FDQEHFRQQHFWHGWRWKHEOHHGRIIYDOYHDQGDFDQVKRXOGEHXVHGWRFDWFKWKHJDV
OLTXLGZKLFKLVEOHGRII$KRVHIRUWKLVSXUSRVHFDQEHVXSSOLHGE\0HWDO6DPSOHV
7KHEOHHGRIIYDOYHVKRXOGEHOHIWRSHQDVORQJDVWKHUHLVOLTXLGFRPLQJRXWIURPWKH
UHWULHYHU7Ke purpose of this isWRJHWDVPXFKOLTXLGDVSRVVLEOHRXWRIWKH
UHWULHYHUEHIRUHLWLVGLVFRQQHFWHGIURPWKHVHUYLFHYDOYH
:$51,1*:KHQEOHHGLQJRIIVRXUJDVRURWKHUGDQJHURXVJDVHVIOXLGVDKRVHPXVW
Hose
Can
Fig. 9
EHXVHGDQGHYHU\SUHFDXWLRQSRVVLEOHPXVWEHWDNHQWRHQVXUHWKDWWKHRSHUDWRUVDUH
QRWHQGDQJHUHG
7KHSURFHGXUHIRUEOHHGLQJRIIGDQJHURXVVXEVWDQFHVZLOOEHGLIIHUHQWIRUGLIIHUHQW
VLWXDWLRQVDQGWKHUHIRUHWKLVPDQXDOFDQQRWJLYHDQ\GHWDLOHGGHVFULSWLRQRIVXFKDQ
RSHUDWLRQ,ILQGRXEWFRQWDFW\RXUVXSSOLHUIRUIXUWKHUDGYLFH
:LWKWKHSUHVVXUHLQWKHUHWULHYHUUHGXFHGWRLWPXVWEHFKHFNHGWKDWWKHVHUYLFHYDOYH
is sealing properly. This can be done by closing the bleed-off valve, and leaving it closed
for 1-2 minutes. Then open it again, to see if there has been any pressure build-up inside
the retriever. If the service valve leaks, then check if it is properly closed. Also check that
the by-pass valve is closed. If leaks in the valve cannot be stopped, the plug / probe must
be reinstalled (see installation procedure, section 4.5, steps 7- 12), and the valve must
be serviced.
For systems containing high pressure dry gas, it can be difficult to make the Service
Valve to seal properly after the plug / probe has been retrieved. This is because it is
difficult to reduce the pressure in the retriever quickly enough (through the bleed valve) to
create the difference in pressure that is required to force the ball against its seat. To
assist in creating this difference in pressure, the retriever can be utilized by pumping in
"RETRIEVE" mode, as this will increase the volume inside the retriever.
If the plug / probe has been fully retrieved already, the pump must be set to "INSTALL"
and the plug / probe pumped towards the ball in the service Valve. Be very carefully
during this pumping, to avoid having the probe coming in contact with the ball, as this
might damage both the probe and the ball. Watch the pressure gauge carefully, and stop
pumping immediately as soon as the pressure starts to increase.
Open the bleed valve on the retriever, set the pump back to "RETRIEVE", and pump as
fast as possible. This will cause the pressure drop in the retriever, and should be
sufficient to make the ball seal against its seat.
,IWKHJDVVWLOOFDQQRWEHEOHGRIIWKHQFORVHWKHEOHHGRIIYDOYH3XPSWKHSOXJEDFNLQWR
WKHDFFHVVILWWLQJWLJKWHQORFNLQJSLQVUHPRYHWKHVHUYLFHYDOYHDQGSHUIRUP
PDLQWHQDQFHRQWKHVHUYLFHYDOYHFKHFNWKHEDOODQGVHDOLQJVHDWVIRUVFUDSHPDUNV
24. )RUGRXEOHLVRODWLRQYDOYHVRQO\:KHQWKHORZHUEDOOLVFORVHGDQGLWLVVHDOLQJ
SURSHUO\FORVHWKHXSSHUEDOO7RXWLOL]HWKHDGGHGVDIHW\RIWKHGRXEOHLVRODWLRQYDOYHLW
LVLPSRUWDQWWRYHULI\WKHIXQFWLRQRIWKHORZHUEDOOEHIRUHXSSHUEDOOLVFORVHG
25. 3URYLGHGWKHVHUYLFHYDOYHLVVHDOLQJSURSHUO\WKHUHWULHYHUFDQQRZEHGLVFRQQHFWHGIURP
WKHYDOYH/RRVHQWKHKDPPHUQXWDQGXQVFUHZLWIURPWKHYDOYH7KHQOLIWWKHUHWULHYHU
DZD\IURPWKHVHUYLFHYDOYH
,IWKHDFFHVVILWWLQJLVLQR
FORFNSRVLWLRQEHDZDUHRIOLTXLGWKDWPLJKWIORZRXWDVWKH
UHWULHYHULVGLVFRQQHFWHGIURPWKHVHUYLFHYDOYH
,IWKHDFFHVVILWWLQJLVLQR
FORFNSRVLWLRQWKHUHWULHYHUPLJKWVWLOOEHILOOHGZLWKOLTXLGDQG
WKHUHIRUHDIWHUEHLQJGLVFRQQHFWHGLWPXVWEHKHOGLQWKHVDPHSRVLWLRQXQWLOLWFDQEH
HPSWLHGLQWRan appropriate container
,03257$170DNHVXUHLWLVRQO\WKHUHWULHYHUWKDWLVORRVHQHGIURPWKHVHUYLFHYDOYH
DQGWKDWWKHVHUYLFHYDOYHis still NHSWSURSHUO\WLJKWHQHGRQWRWKHDFFHVVILWWLQJ
26. 3ODFHWKHUHWULHYHUZLWKWKHRSHQLQJXSDQGVHWWKHSXPSWR,167$//3XPSWKH
SOXJ SUREHDVVHPEO\RXWRIWKHUHWULHYHU7KHSUREHDQGSOXJFDQQRZEHLQVSHFWHGDQG
VHUYLFHGRUUHSODFHGILJ
Probe
Plug
Fig. 10
,QVWDOODWLRQRID0RQLWRULQJ'HYLFHLQWRD3UHVVXUL]HG3LSH
7KHLQVWDOODWLRQSURFHGXUHVWDUWVZKHUHWKHUHWULHYDOSURFHGXUHHQGHG(LHZLWKDK\GUDXOLFDFFHVV
ILWWLQJRQDSUHVVXUL]HGOLQHZLWKRXWDSOXJLQVLGHDQGZLWKDFORVHGVHUYLFHYDOYHPRXQWHGRQWR
WKHILWWLQJWRFRQWDLQWKHOLQHSUHVVXUH).
%HIRUHVWDUWLQJWKHLQVWDOODWLRQPDNHVXUHWKDWWKHUHWULHYHULVFOHDQDQGUHDG\IRUXVH(UHIVHFWLRQ
5RXWLQHLQVSHFWLRQEHIRUHXVH)
3ODFHWKHUHWULHYHUZLWKWKHRSHQLQJXSZDUGVDQGFRQQHFWWKHKRVHVIURPWKHSXPS6HWWKH
SXPSWR,167$//DQGSXPSXQWLOWKHFRQQHFWLQJURGLVH[WHQGHG
0RXQWWKHSOXJSUREHWRWKHFRQQHFWLQJURG6HWWKHSXPSWR5(75,(9(DQGSXPSXQWLOWKH
SUREHKDVEHHQIXOO\UHWUDFWHGLQWRWKHUHWULHYHUILJ
Probe
Fig. 11
/LIWWKHUHWULHYHURQWRWKHVHUYLFHYDOYHVFUHZWKHKDPPHUQXWRQWRWKHYDOYHDQGWLJKWHQLW
6HWWKHSXPSWR,167$//
%DODQFHSUHVVXUHVRQERWKVLGHVRIWKHVHUYLFHYDOYHE\
x IRUVWDQGDUGVHUYLFHYDOYHVVORZO\RSHQLWVE\SDVVYDOYH7KHSUHVVXUHLQWKH
UHWULHYHUZLOOQRZLQFUHDVHXQWLOLWHTXDOVWKHOLQHSUHVVXUH7KHSUHVVXUHFDQEHUHDGRQ
WKHUHWULHYHUSUHVVXUHJDXJH
x IRUGRXEOHLVRODWLRQVHUYLFHYDOYHVVORZO\RSHQWKHE\SDVVYDOYHIRUWKHXSSHUEDOO
FORVHVWWRWKHUHWULHYHUDQGWKHQRSHQWKHXSSHUEDOOLWVHOI1RUPDOO\WKHUHZLOOEHQR
SUHVVXUHEHKLQGWKLVEDOOEXWLWVKRXOGEHRSHQHGFDUHIXOO\DQ\ZD\LQFDVHWKHUHLVDOHDN
SDVWWKHORZHUEDOO1RZVORZO\RSHQWKHE\SDVVYDOYHIRUWKHORZHUEDOO7KHSUHVVXUHLQ
WKHUHWULHYHUZLOOQRZLQFUHDVHWROLQHSUHVVXUH
,IWKHSUHVVXUHVFDQQRWEHEDODQFHGPRVWOLNHO\GXHWRGLUWLQWKHE\SDVVYDOYHLWZLOO
EHGLIILFXOWWRRSHQWKHVHUYLFHYDOYHHVSHFLDOO\ZKHQWKHOLQHSUHVVXUHLVKLJKDERYH
SVLEDU7KHSUHVVXUHVKRXOGWKHQEHEDODQFHGE\XVHRIWKHSXPS
7REDODQFHWKHSUHVVXUHVZLWKWKHSXPSXVHWKHIROORZLQJVWHSV
x 6HWWKHSXPSWR5(75,(9(DQGSXPSXQWLOWKHSUREHLVIXOO\UHWULHYHG
x 'LVFRQQHFWWKHKRVHIURPWKHIHPDOHTXLFNFRXSOLQJRQWKHPLGGOHRIWKHUHWULHYHUDQG
FRQQHFWLWWRWKH%DFN3UHVVXUH4XLFN&RXSOLQJ$VV\RQWKH%OHHGRII9DOYH(QVXUHWKDW
WKHEOHHGYDOYHLVRSHQILJ
x .HHSWKHSXPSLQ5(75,(9(SRVLWLRQDQGSXPSXQWLOWKHSUHVVXUHLQVLGHWKHUHWULHYHU
HTXDOVRUH[FHHGVWKHOLQHSUHVVXUH7KHQFORVHWKH%OHHGRII9DOYH
x 0RYHWKHKRVHIURPWKH%OHHGRII9DOYHEDFNWRLWVRULJLQDOSRVLWLRQ
x &KHFNDQGPDNHVXUHWRKDYHHQRXJKK\GUDXOLFRLOLQVLGHWKHSXPS
Fig. 12
:LWKWKHOLQHSUHVVXUHLQWKHUHWULHYHUFKHFNIRUOHDNVEHWZHHQWKHUHWULHYHUDQGWKH
VHUYLFHYDOYH,IQROHDNVRFFXURSHQWKHVHUYLFHYDOYH)RUGRXEOHLVRODWLRQYDOYHV
RSHQWKHORZHUEDOO
6HWWKHSXPSWR,167$//DQGSXPSXQWLOWKHSOXJSUREHLVLQVWDOOHGLQWRLWVSRVLWLRQ
LQVLGH WKH DFFHVV ILWWLQJ 7KH QXPEHU RI SXPS VWURNHV UHTXLUHG IRU WKLV RSHUDWLRQ
GHSHQGVXSRQWKHOLQHSUHVVXUHDQGWKHVL]HRIWKHUHWULHYHU
,I XVLQJ DQ DLU SXPS WKH WLPH UHTXLUHG IRU WKLV RSHUDWLRQ ZLOO EH DSSUR[LPDWHO\
VHFRQGV:KHQWKHSOXJSUREHLVLQSRVLWLRQLQVLGHWKHK\GUDXOLFDFFHVVILWWLQJWKHJDXJH
RQWKHSXPSZLOOVKRZWKDWWKHSUHVVXUHLQVLGHWKHUHWULHYHULQFUHDVHVIRUHDFKQHZSXPS
VWURNH ZLWKRXW GURSSLQJ DIWHUZDUGV 7KH UHWULHYHU SUHVVXUH VKRXOG QRZ EH LQFUHDVHG WR
SVL EDU DERYH OLQH SUHVVXUH LQ RUGHU WR HQVXUH WKDW WKH SULPDU\
SDFNLQJRQWKHSOXJJHWVSURSHUO\SRVLWLRQHGLQWRLWVVHDW
8. %OHHG RII WKH SUHVVXUH LQVLGH WKH VHUYLFH YDOYH E\ RSHQLQJ WKH UHWULHYHU
V RU VHUYLFH
YDOYH
VEOHHGRIIYDOYHFDUHIXOO\8VHDKRVHDQGDFDQWRGRWKLVLQDFRQWUROOHGPDQQHU
7KHVDPHVDIHW\SUHFDXWLRQVDVIRUUHWULHYDORSHUDWLRQVVKDOODSSO\VHHVHFWLRQVWHS
IRUIXUWKHUDGYLFH
9. 7LJKWHQDOOORFNLQJSLQVRQWKHDFFHVVILWWLQJ7KHSLQVPXVWEHWLJKWHQHGHYHQO\DURXQG
WKH DFFHVV ILWWLQJ LQ RUGHU WR DYRLG WKH SOXJEHLQJ SXVKHG DJDLQVW RQH VLGH RI WKH ILWWLQJ
7KHUHIRUH VFUHZ LQ DOOSLQV XQWLO WKH\ WRXFK WKH SOXJ 7KHQ WLJKWHQ RQH E\ RQH ILJ
DSSUR[RIDWXUQDQGUHSHDWXQWLODOOORFNLQJSLQVDUHVXIILFLHQWO\WLJKWHQHG([SHFW
D WRWDORIWXUQVIRUDGHTXDWHWLJKWHQLQJ
,IWKHORFNLQJSLQVVXGGHQO\VWRSDIWHURQO\WXUQVRULIWKH\FDQHDVLO\EHVFUHZHGDOOWKH
ZD\LQWXUQVZLWKRXWDQ\UHVLVWDQFHWKLVLQGLFDWHVWKDWWKHSOXJLVQRWTXLWHLQSRVLWLRQ
/RRVHQ DOO SLQV UHWULHYH WKH SOXJ SUREH DVVHPEO\ DJDLQ DQG ORRN IRU GDPDJHV WKDW
PLJKWSUHYHQWSURSHULQVWDOODWLRQVHHVHFWLRQVWHSs
3
4
Fig. 13
10. :KHQWKHSOXJLVIL[HGLQSRVLWLRQE\WKHORFNLQJSLQVWKHSUHVVXUHLQWKHUHWULHYHUFDQ
UHOHDVHG6HWWKHSXPSWR5(75,(9(DQGSXPSVWURNHV7KHJDXJHRQWKHSXPS
VKDOOQRZVKRZ
11. &ORVHWKHEOHHGRIIYDOYHDQGZDLWIRUPLQXWHV7KHQRSHQLWDJDLQDQGVHHLISUHVVXUH
KDVEXLOWXSLQVLGHWKHUHWULHYHU$SUHVVXUHEXLOGXSLQGLFDWHVWKDWWKHSOXJLVQRWVHDOLQJ
SURSHUO\LQWKHDFFHVVILWWLQJ,IWKLVKDSSHQVXVHWKHSXPSWRLQFUHDVHWKHUHWULHYHUSUHVVXUH
WRDOHYHODWOHDVWSVLEDUDERYHSLSHOLQHSUHVVXUH7KHQORRVHQWKHORFNLQJSLQV
DQGUHWLJKWHQWKHP&KHFNDJDLQLIWKHOHDNVDUHVWLOOWKHUH,IVRWKHSOXJPXVWEHSXOOHG
RXWIRULQVSHFWLRQUHSODFHPHQWRIWKHSULPDU\SDFNLQJ6HHLQVWUXFWLRQIRUUHWULHYDO
VHFWLRQVWHSs
12. 3URYLGLQJQROHDNVRFFXUWKHUHWULHYHUFDQEHUHPRYHG/RRVHQWKHKDPPHUQXWDQG
XQVFUHZLWFRPSOHWHO\IURPWKHVHUYLFHYDOYH%HDZDUHthatIOXLGPLJKWIORZRXWZKHQ WKH
UHWULHYHULVEHLQJGLVFRQQHFWHG6HWWKHSXPSWR,167$//DQGSXPSXQWLOWKH
FRQQHFWLQJURGLVIXOO\H[WHQGHG&RQWLQXHWRSXPSXQWLOWKHJDXJHRQWKHSXPSVKRZV
WKDWWKHSUHVVXUHLQVLGHWKHUHWULHYHULVDWOHDVWSVLEDU7KHQFORVHWKHUHWULHYHU
KHDGYDOYHDQGUHOHDVHWKHSUHVVXUHLQWKHSXPSKRVH
'LVFRQQHFWWKHKRVHVIURPWKHUHWULHYHUDQGWKHQXQVFUHZWKHUHWULHYHUFRQQHFWLQJURGIURP
WKHSOXJE\URWDWLQJWKHUHWULHYHU
13. 8VHWKHKDPPHUWRORRVHQWKHVHUYLFHYDOYHIURPWKHK\GUDXOLFDFFHVVILWWLQJ5HPRYH
WKHYDOYH
127(,IDSUREHZLWKDQHOHFWULFDOFRQQHFWRUKDVEHHQLQVWDOOHGWKHSUREHFRQQHFWRUPXVW
EHFOHDQHGWKRURXJKO\ZLWKDFOHDQVLQJDJHQWVXLWDEOHIRUHOHFWULFDOHTXLSPHQW
Pipe Plug
Fig. 14
7UDLQLQJSURJUDPIRU2SHUDWRUV
&+$37(5±0DLQWHQDQFH
*HQHUDO
,QWURGXFWLRQ
$pURSHUDQGUHJXODUPDLQWHQDQFHLVYHU\LPSRUWDQWLQRUGHUWRHQVXUHWURXEOHIUHHRSHUDWLRQ
RIWKH'RXEOH$FWLQJ+\GUDXOLF5HWULHYDO7RRODQGWRNHHSLWLQJRRGRSHUDWLQJFRQGLWLRQ
RYHUDORQJSHULRGRIWLPH
0DLQWHQDQFHLQVWUXFWLRQV
5RXWLQH,QVSHFWLRQVEHIRUHXVH
$IWHUDVWRUDJHSHULRGWKHUHWULHYHUPXVWEHFKHFNHGWRHQVXUHWKDWLWLVLQRSHUDWLRQDO
FRQGLWLRQEHIRUHEHLQJXVHG7KHFKHFNSRLQWVGHVFULEHGLQWKLVVHFWLRQDVVXPHWKH
UHWULHYHUKDVEHHQSURSHUO\FOHDQHGDQGPDLQWDLQHGDIWHULWVODVWXVH,ILQGRXEWIROORZWKH
PDLQWHQDQFHLQVWUXFWLRQVLQVHFWLRQLQVWHDG
,IWKHUHWULHYHULVWREHXVHGRYHUDSHULRGRIVHYHUDOGD\VWKLVFKHFNVKRXOGDOVREH
SHUIRUPHGGDLO\EHIRUHWKHILUVWUHWULHYDORSHUDWLRQ
5.2.1.2 Service Valve
&KHFNWKDWDOOSDUWVDUHSUHVHQWHVSHFLDOO\WKHEROWVFRQQHFWLQJWKHYDOYHVHFWLRQVWRJHWKHU
&KHFNWKDWWKHVHUYLFHYDOYHLVFOHDQDQGXQGDPDJHGERWKH[WHUQDOO\DQGLQWHUQDOO\
&KHFNWKDWWKHVHUYLFHYDOYHFDQEHRSHQHGDQGFORVHGHDVLO\
&KHFNWKDWWKHUHDUHQRGHHSVFUDWFKHVRURWKHUGDPDJHVLQWKHVXUIDFHRIWKH%DOOV
0LQRUVFUDWFKHVZLOOXVXDOO\QRWFDXVHDQ\SUREOHPV
3HULRGLF0DLQWHQDQFH
7KHUHLVQRVHWPDLQWHQDQFHSHULRG7KHPDLQWHQDQFHSHULRGLVEDVHGRQWKHQXPEHU
RIXVHVDQGRUGHSHQGRQWKHFRQGLWLRQVXQGHUZKLFKWKHHTXLSPHQWLVEHLQJXVHG
,IWKHUHWULHYHULVXVHGRQSLSHV\VWHPVFRQWDLQLQJODUJHDPRXQWVRIVDQGRURWKHUGHEULV
LWPD\EHQHFHVVDU\WRJRWKURXJKWKHPDLQWHQDQFHURXWLQHTXLWHIUHTXHQWO\WRNHHSWKH
UHWULHYHUVXIILFLHQWO\FOHDQGXULQJRSHUDWLRQV,QVHYHUHFDVHVLHKLJKTXDQWLWLHVRIVDQGLQ
WKHSLSLQJV\VWHPLWPLJKWEHUHTXLUHGWRFOHDQWKHUHWULHYHUDIWHUHDFKVLQJOHUHWULHYDO
RSHUDWLRQ7KLVLVWRSUHYHQWKLJKZHDUDQGRURWKHUGDPDJHVWRWKHLQWHUQDOVRIWKH
UHWULHYHU7RSHUIRUPSHULRGLFFOHDQLQJIROORZWKHLQVWUXFWLRQVLQVHFWLRQ
'LVDVVHPEO\DQGFOHDQLQJ
0DLQWHQDQFH$IWHU8VH
:KHQDVHULHVRIUHWULHYDORSHUDWLRQVDUHFRPSOHWHGDQGWKHK\GUDXOLFUHWULHYHULVWREH
VWRUHGIRUDZKLOHLWVKRXOGEHGLVDVVHPEOHGFOHDQHGDQGFKHFNHGIROORZLQJWKH
SURFHGXUHEHORZ
'LVDVVHPEO\DQGFOHDQLQJ
&RQQHFWWKHKRVHVIURPWKHSXPS6HWWKHSXPSWR5(75,(9(DQGSXPSXQWLOWKH
LQQHUEDUUHODQGFRQQHFWLQJURGLVIXOO\UHWUDFWHGLQWRWKHUHWULHYHU
/RRVHQWKHVL[EROWVRQWKHPDLQF\OLQGHUKHDGDQGUHPRYHWKHPDLQF\OLQGHUKHDG
DQGWKHSURWHFWLRQULQJ
4. 8QVFUHZWKHZDVKHUIURPWKHHQGRIWKHFRQQHFWLQJURGDQGSXVKWKHURGRXWRIWKH
LQQHUEDUUHO7KHUHWULHYHULVQRZVXIILFLHQWO\GLVDVVHPEOHGIRUFOHDQLQJDQGLQVSHFWLRQ
7KHIROORZLQJVWHSVDQGVKRXOGRQO\EHSHUIRUPHGLIWKHXQLRQWKUHDGDGDSWHU
(cylinder bottom end cap)SUHVVXUHJDXJHEOHHGYDOYHRUF\OLQGHUKHDGYDOYHDUH
GHIHFWiveRUOHDNVKDYHRFFXUUHGLQ or around WKHVHSDUWV
5. /RRVHQWKHVHWVFUHZ0[RQWKHXQLRQWKUHDGDGDSWHU8QVFUHZWKHXQLRQWKUHDG
DGDSWHUIURPWKHPDLQF\OLQGHUXVHDVSHFLDOKRRNZUHQFKDQGUHPRYHWKHKDPPHU
QXW
6. 8QVFUHZWKHSUHVVXUHJDXJHWKHEOHHGYDOYHIURPWKHF\OLQGHU
7. 8QVFUHZWKHF\OLQGHUKHDGYDOYHDVVHPEO\E\XQVFUHZLQJWKHYDOYHKRXVLQJ/RRVHQ
WKHVHWVFUHZ0[DQGUHPRYHWKHKDQGOHIURPWKHYDOYHVWHP8QVFUHZWKHJODQG
IURPWKHYDOYHKRXVLQJ8QVFUHZWKHYDOYHVWHP IURPWKHYDOYHKRXVLQJ5HPRYHVHDOV
DQGFRPSUHVVLRQULQJIURPWKHYDOYHKRXVLQJ
8. 5HPRYHDOO2ULQJVEDFNXSULQJVDQGZHDUULQJVEXWOHDYHWKHZLSHUULQJRQWKH LQQHU
EDUUHOLQSODFH7KHVHULQJVDUHYHU\HDVLO\GDPDJHGZKHQWKH\DUHUHPRYHGDQG
VKRXOGWKHUHIRUHRQO\EHUHPRYHGZKHQWKH\DUHZRUQRXWDQGQHHGWREHUHSODFHG
9. &OHDQDOOSDUWVWKRURXJKO\ZLWKDVXLWDEOHGHWHUJHQWHVSHFLDOO\WKHLQWHUQDOVRIWKHPDLQ
F\OLQGHUWKH2ULQJVDQGZHDUULQJVDQGWKHLUJURRYHVRQWKHLQQHUEDUUHODQG
FRQQHFWLQJURG
10.&KHFNWKHVHDOVDQGZHDUULQJVFDUHIXOO\,IDQ\RIWKHVHDOVKDYHVFUDWFKHVRUVKRZ
RWKHUVLJQVRIZHDUWKH\PXVWEHUHSODFHG,IDQ\RIWKHZLSHUULQJVRQWKHLQQHUEDUUHO
QHHGWREHUHSODFHGVHHLQVWUXFWLRQVIRU5HSODFHPHQWRIZLSHUULQJVLQWKHIROORZLQJ
VHFWLRQ
11.&KHFNDOOSDUWVIRUGDPDJHHVSHFLDOO\WKHLQWHUQDOVXUIDFHVRIWKHPDLQF\OLQGHUDQG
WKHLQQHUEDUUHO
,IDOOSDUWVLQFOXGLQJVHDOVDUHIRXQGWREHLQJRRGFRQGLWLRQWKHUHWULHYHUFDQEHDVVHPEOHG
DJDLQ7KHDVVHPEO\VKDOOWDNHSODFHLQWKHUHYHUVHRUGHURIWKHGHVFULEHGGLVDVVHPEO\
SURFHGXUH
%HDEVROXWHO\FHUWDLQWKDWDOOWKUHDGHGVXUIDFHVDUHFOHDQHGIURPSDUWLFOHVVDQGPHWDO
SDUWLFOHVHWFDQGSURSHUO\OXEULFDWHGEHIRUHDQ\RIWKHSDUWVDUHPRXQWHGWRJHWKHU7KLV
LVHVSHFLDOO\LPSRUWDQWZKHQPRXQWLQJWKHXQLRQWKUHDGDGDSWHU (cylinder bottom
end cap)WRWKHPDLQF\OLQGHU8VHDKLJKTXDOLW\DQWLVHL]HOXEULFDQWHJ&RSDVOLS
0RO\VOLSRUVLPLODUW\SHV
$IWHUDOOVHDOVKDYHEHHQLQVWDOOHGinWKHFRUUHFWORFDWLRQVXVH2ULQJJUHDVHWROXEULFDWH
WKHVHDOVHVSHFLDOO\EHIRUHWKHFRQQHFWLQJURGLVLQVWDOOHGLQWRWKHLQQHUEDUUHOEHIRUH
WKHLQQHUEDUUHOLVLQVWDOOHGLQWRWKHPDLQF\OLQGHUDQGEHIRUHWKHXQLRQWKUHDGDGDSWHU
(cylinder bottom end cap) LVLQVWDOOHGRQWKHPDLQF\OLQGHU
%HFDUHIXOZKHQSXWWLQJWKHSDUWVEDFNWRJHWKHU6SHFLDOFDUHVKRXOGEHWDNHQWRHQVXUH
WKDWWKHVHDOVDUHQRWGDPDJHGZKHQWKHFRPSRQHQWVDUHDVVHPEOHG
,IWKHTXLFNFRXSOLQJVDUHUHPRYHGIURPWKHPDLQF\OLQGHUIRUPDLQWHQDQFHRU
UHSODFHPHQWPDNHVXUHWKDWWKH\DUHUHLQVWDOOHGLQFRUUHFWSRVLWLRQV7KHPDOHRQH
VKDOOEHLQVWDOOHGRQWKHUHWULHYHUKHDGZKLOHWKHfePDOHRQHVKDOOEHLQVWDOOHGiQWKH
PLGGOHRIWKHUHWULHYHUPDLQF\OLQGHU
,03257$17,IWKHEROWVIRUWKHUHWULHYHUKHDGDUHWREHUHSODFHGDOZD\VUHSODFHWKHP
ZLWKQHZRULJLQDOEROWVIURP0HWDO6DPSOHV
7KHWLJKWHQLQJWRUTXHIRUWKH0EROWVRQWKHUHWULHYHUKHDGLVIWOEV1P
5HSODFHPHQWRIZLSHUULQJV
7KHK\GUDXOLFUHWULHYHUKDVRQHZLSHUULQJLQVWDOOHGRQWKHLQQHUEDUUHO:KHQWKLVZLSHU
ULQJVLVGDPDJHGDQGQHHGWREHUHSODFHGWKHIROORZLQJLQVWUXFWLRQVVKRXOGEHIROORZHG
3OHDVHQRWHWKDWQHZZLSHUULQJZLOOEHDORWHDVLHUWRLQVWDOODQGIRUPWRVKDSHLILWDUH
KHDWHGILUVW+HDWLQJVKDOOEHGRQHE\NHHSLQJWKHZLSHUULQJLQERLOLQJZDWHUIRUDIHZ
PLQXWHV'R127DWWHPSWWRKHDWWKHZLSHUVLQDQ\RWKHUZD\
,QWHUQDOZLSHUVHHILJXUHGUDZLQJLQVHFWLRQ
1. 0DNHVXUHDQHZZLSHURIFRUUHFWW\SHLVDYDLODEOH7KH,QWHUQDOZLSHU LVLQVWDOOHG
WRJHWKHUZLWKDQ2ULQJLQDFRPPRQJURRYH
2. 5HPRYHWKHROGZLSHUIURPWKHJURRYHby using an appropriate tool (i.e.DVPDOO
VFUHZGULYHU)
3. 5HPRYHWKH2ULQJthat is LQVWDOOHGLQWKHVDPHJURRYHXQGHUWKHZLSHU
4. &OHDQWKHJURRYHthoroughly
5. ,QVWDOODQHZ2ULQJLQWRWKHJURRYHDQGSODFHLWLQWKHJURRYHDVVKRZQRQWKH
GUDZLQJ
6. )RUPWKHZLSHULQWRDNLGQH\VKDSHZLWKRXWFUHDWLQJDQ\VKDUSEHQGVILJ
7. 3ODFHWKHGHIRUPHGZLSHULQWKHJURRYHRYHUWKH2ULQJDQGPDNHVXUHWKH
RULHQWDWLRQLVFRUUHFWZLWKWKHSRLQWHGFOHDQLQJVLGHRIWKHZLSHUIDFLQJRXWRIWKH
LQQHUEDUUHODVSHUILJ
8. :LWKWKHZLSHUSODFHGLQWKHJURRYHUHIRUPLWEDFNWRLWVRULJLQDOVKDSH.First,XVH D
ILQJHURUDVPDOOURXQGREMHFW:KHQWKHZLSHULVURXJKO\IRUPHGWRVKDSHLQWKH
JURRYHILQDOVKDSHFDOLEUDWLRQcanEHperformedE\XVingan optionalinstallation
tool 7KLVtool KDVDVKDIWVHFWLRQZLWKGLDPHWHU´PP6OLGHWKHWDSHUHGHQG
RIWKHVKDIWFDUHIXOO\LQWRWKHZLSHU. Then,SXVKWKHtoolLQWRWKHLQQHUEDUUHOXQWLO LW
VWRSV.HHSLWLQWKLVSRVLWLRQIRUPLQXWHV7KHLQWHUQDOZLSHULVQRZUHDG\IRU XVH
Fig. 15
3UHVHUYDWLRQ
,IWKHUHWULHYDOWRROLVWREHVWRUHGDIWHUPDLQWHQDQFHLWVKRXOGEHSUHVHUYHGZLWKD0XOWL3XUSRVH
/XEULFDQW0DNHVXUHWRVHOHFWDW\SHWKDWDOVRZLOOGULYHRXWPRLVWXUHDQGSURWHFWDJDLQVWFRUURVLRQ
5.2.3.2 Single Isolation Service Valve
0DLQWHQDQFHRIWKH6HUYLFH9DOYHLVEDVLFDOO\GHWHUPLQHGE\WKHHQYLURQPHQWLQWKH
SURFHVVSLSH3UHVHQFHRIVDQGRURWKHUGHSRVLWVZLOOUHTXLUHIUHTXHQWFOHDQLQJRIWKH
YDOYHPD\EHDVRIWHQDVDIWHUHDFKUHWULHYDOLQVWDOODWLRQRSHUDWLRQZKLOHZKHQXVHGZLWK
FOHDQOLTXLGVDGDLO\FOHDQLQJPLJKWEHVXIILFLHQW
$IWHUHDFKXVHFKHFNto see LIWKHYDOYHFDQHDVLO\EHRSHQHGFORVHG,IWKHURWDWLRQRI
WKHEDOOLVREVWUXFWHGE\GLUWLWPXVWEHFOHDQHG)RUTXLFNFOHDQLQJFRPSUHVVHGDLUFDQ
EHEORZQLQVLGHWKHYDOYHDURXQGWKHEDOOWRUHPRYHDOOGHSRVLWV7KHQOXEULFDWHWKHEDOO
ZLWKRLODQGFKHFNWKDWLWURWDWHVSURSHUO\EHIRUHQH[WXVH,IWKLVLVQRWVXFFHVVIXOWKH
YDOYHPXVWEHGLVDVVHPEOHGDQGVHUYLFHGDVGHVFULEHGEHORZ
%HIRUHVWRUingWKHVHUYLFHYDOYHLWVKRXOGEHGLVDVVHPEOHGDQGFOHDQHGSURSHUO\DV
GHVFULEHGLQWKHIROORZLQJLQVWUXFWLRQV
'LVDVVHPEO\DQGFOHDQLQJ
5HPRYHWKHKDQGOH
/RRVHQWKHVL[EROWV0[DQGUHPRYHWKHWRSIODQJH
5RWDWHWKHEDOOVWHPWRFORVHGSRVLWLRQDQGWKHQUHPRYHWKHEDOO
5HPRYHWKHUHWDLQLQJULQJ
5HPRYHWKHVWHPVWRSULQJ
3XVKWKHEDOOVWHPLQWRWKHPDLQERG\
,IWKHPDLQVHDOQHHGVUHSODFHPHQWWKHQXQVFUHZWKHVHDOFDUULHU
8QVFUHZDQGUHPRYHWKHE\SDVVYDOYHVWHP
&KHFNDQGUHSODFHWKHE\SDVVYDOYHVWHP2ULQJLIGDPDJHG
,03257$17 ,I WKH EROWV IRU WKH 6HUYLFH 9DOYH %RG\ DUH WR EH UHSODFHG DOZD\V
UHSODFHWKHP ZLWK QHZ RULJLQDO EROWV IURP 0HWDO 6DPSOHV
7KHWLJKWHQLQJWRUTXHIRUWKH0EROWVLVIWOEV1P
3UHVHUYDWLRQ
,IWKH6HUYLFH9DOYHLVWREHVWRUHGDIWHUPDLQWHQDQFHLWVKRXOGEHSUHVHUYHGZLWKD
0XOWL3XUSRVH/XEULFDQW0DNHVXUHWRVHOHFWDW\SHWKDWDOVRZLOOGULYHRXWPRLVWXUHDQG
SURWHFWDJDLQVWFRUURVLRQ
5.2.3.3 Double Isolation Service Valve
0DLQWHQDQFHRIWKH6HUYLFH9DOYHLVEDVLFDOO\GHWHUPLQHGE\WKHHQYLURQPHQWLQWKH
SURFHVVSLSH3UHVHQFHRIVDQGRURWKHUGHSRVLWVZLOOUHTXLUHIUHTXHQWFOHDQLQJRIWKH
YDOYHPD\EHDVRIWHQDVDIWHUHDFKUHWULHYDOLQVWDOODWLRQRSHUDWLRQZKLOHZKHQXVHG
ZLWKFOHDQOLTXLGVDGDLO\FOHDQLQJPLJKWEHVXIILFLHQW
$IWHUHDFKXVHFKHFNto see LIWKHYDOYHFDQHDVLO\EHRSHQHGFORVHG,IWKH
URWDWLRQRIWKHEDOOLVREVWUXFWHGE\GLUWLWPXVWEHFOHDQHG)RUTXLFNFOHDQLQJ
FRPSUHVVHGDLUFDQEHEORZQLQVLGHWKHYDOYHDURXQGWKHEDOOWRUHPRYHDOO
GHSRVLWV7KHQOXEULFDWHWKHEDOOZLWKRLODQGFKHFNWKDWLWURWDWHVSURSHUO\EHIRUH
QH[WXVH,IWKLVLVQRWVXFFHVVIXOWKHYDOYHPXVWEHGLVDVVHPEOHGDQGVHUYLFHGDV
GHVFULEHGEHORZ
%HIRUHstoring the service valveLWVKRXOGEHGLVDVVHPEOHGDQGFOHDQHGSURSHUO\DV
GHVFULEHGLQWKHIROORZLQJLQVWUXFWLRQV
'LVDVVHPEO\DQGFOHDQLQJ
5HPRYHWKHKDQGOH
/RRVHQWKHVL[EROWV0[DQGUHPRYHWKHWRSIODQJH
5RWDWHWKHEDOOVWHPRIWKHXSSHUERG\WRFORVHGSRVLWLRQDQGWKHQUHPRYH
WKHEDOO
5HPRYHWKHUHWDLQLQJULQJ
5HPRYHWKHVWHPVWRSULQJ
3XVKWKHEDOOVWHPLQWRWKHXSSHUERG\
5HSHDWVWHSVIRUORZHUERG\
,IWKHPDLQVHDOVQHHGUHSODFHPHQWWKHQXQVFUHZWKHVHDOFDUULHUV
8QVFUHZDQGUHPRYHWKHE\SDVVYDOYHVWHP
&KHFNDQGUHSODFHWKHE\SDVVYDOYHVWHP2ULQJLIGDPDJHG
,03257$17,IWKHEROWVIRUWKH6HUYLFH9DOYH%RG\DUHWREHUHSODFHGDOZD\V
UHSODFHWKHPZLWKQHZRULJLQDOEROWVIURP0HWDO6DPSOHV
7KHWLJKWHQLQJWRUTXHIRUWKH0EROWVLVIWOEV1P
3UHVHUYDWLRQ
,IWKH'RXEOH6HUYLFH9DOYHLVWREHVWRUHGDIWHUPDLQWHQDQFHLWVKRXOGEH
SUHVHUYHGZLWKD0XOWL3XUSRVH/XEULFDQW0DNHVXUHWRVHOHFWDW\SHWKDWDOVRZLOO
GULYHRXWPRLVWXUHDQGSURWHFWDJDLQVWFRUURVLRQ
5.2.3.4 Manual (hand operated) Hydraulic Pump
7KHK\GUDXOLFSXPSXVXDOO\GRHVQRWQHHGDQ\VSHFLDOPDLQWHQDQFH+RZHYHUZKHQWKH
SXPSLVWREHVWRUHGIRUan extended period of timeDIWHUDVHULHVRIRSHUDWLRQVWKH
IROORZLQJLQVWUXFWLRQVVKRXOGEHIROORZHG
9LVXDOLQVSHFWLRQ
'RDYLVXDOLQVSHFWLRQRIWKHSXPSDQGKRVHVDQGPDNHVXUHWKDWDOOSDUWVDUHLQJRRG
ZRUNLQJFRQGLWLRQ3D\VSHFLDODWWHQWLRQWRWKHIROORZLQJLWHPV
+RVHV -7KHUHVKDOOEHQRYLVXDOGDPDJHVWRWKHRXWHUlayer RIWKHKRVHV
4XLFNFRQQHFWV -7KHVHVKDOOFRQQHFWDQGGLVFRQQHFWHDVLO\DQGWKHUHVKDOOEHQR
GDPDJHH[WHUQDOO\RULQWHUQDOO\
3UHVVXUHJDXJH -7KHJDXJHVKDOOEHXQGDPDJHGDQGUHDFWLPPHGLDWHO\WR
LQFUHDVHG SUHVVXUH
&KDQJHRLOLQWKHUHVHUYRLU
7KHK\GUDXOLFIOXLGVKRXOGEHUHSODFHGGXHWRWKHSRVVLELOLW\WKDWLWKDVEHHQFRQWDPLQDWHG
ZLWKPRLVWXUHRURWKHUOLTXLGVJDVHVIURPWKHSLSHOLQHWKDWVXEVHTXHQWO\FRXOGFDXVH
FRUURVLRQDWWDFNVLQVLGHWKHSXPS
'RDVIROORZV
x (PSW\WKHWDQNFRPSOHWHO\
x )LOOXSZLWKQHZK\GUDXOLFIOXLG
x &RQQHFWWKHKRVHVWRWKHSXPS
x 8QVFUHZWKHTXLFNFRQQHFWVIURPWKHIUHHHQGVRIWKHKRVHV
x 3XPSVWURNHVLQERWKUHWULHYHDQGLQVWDOOPRGHDQGPDNHVXUHWKDWQHZ
K\GUDXOLFIOXLGLVIORZLQJRXWWKURXJKERWKKRVHV
3XWWKHTXLFNFRQQHFWVEDFNRQWKHKRVHV.
,IDQ\IXUWKHUPDLQWHQDQFHRUUHSDLUVKRXOGEHUHTXLUHGUHSODFHPHQWRIVHDOVHWF
LQVWUXFWLRQVIRUWKLVLVGHVFULEHGLQWKH5HSDLU3DUWV6KHHWZKLFKLVGHOLYHUHGZLWKWKH
SXPS)RUDQ\IXUWKHUPDLQWHQDQFHRUVSDUHSDUWVSOHDVHUHIHUWRWKHSXPSPDQXIDFWXUHU
GLUHFWO\
5.2.3.5 Air operated Hydraulic Pump
%DVLFRSHUDWLRQDQGPDLQWHQDQFHRIWKHDLURSHUDWHGSXPSLVGHVFULEHGWKH,QVWUXFWLRQ
ManualZKLFKLVLQFOXGHGLQWKHUHWULHYHUNLW
,IDQ\IXUWKHUPDLQWHQDQFHRUUHSDLUVKRXOGEHUHTXLUHGUHSODFHPHQWRIVHDOVHWF
LQVWUXFWLRQVIRUWKLVLVGHVFULEHGLQWKH5HSDLU3DUWV6KHHWZKLFKLVGHOLYHUHGZLWKWKH
SXPS)RUDQ\IXUWKHUPDLQWHQDQFHRUVSDUHSDUWVSOHDVHUHIHUVWRWKHSXPSPDQXIDFWXUHU
GLUHFWO\
6WRULQJSUHVHUYDWLRQDQGPDLQWHQDQFHRISUHVHUYDWLRQ
3UHVHUYDWLRQ
$V GHVFULEHG LQ VHFWLRQ LI WKH UHWULHYDO WRRO DQGRU VHUYLFH YDOYH LV WR EH VWRUHG IRU
an extended period of time DIWHU PDLQWHQDQFH WKH HTXLSPHQW VKRXOG EH SUHVHUYHG
ZLWK D 0XOWL3XUSRVH /XEULFDQW 0DNH VXUH WR VHOHFW D W\SH WKDW DOVR ZLOO GULYH RXW
PRLVWXUHDQGSURWHFWDJDLQVWFRUURVLRQ
6WRUDJH
$IWHUWKHHTXLSPHQWKDVEHHQSURSHUO\FOHDQHGPDLQWDLQHGDQGSUHVHUYHGUHIVHFWLRQ
LWVKRXOGEHVWRUHGLQWKHRULJLQDOWUDQVSRUWFDVHVLQZKLFKLWZDVGHOLYHUHG7KHFDVHVVKRXOG
EHGU\DQGFOHDQRQWKHLQVLGHEHIRUHWKHHTXLSPHQWLVEHLQJSODFHGLQWRWKHP
7KHHTXLSPHQWVKDOOEHVWRUHGLQGRRUVLQDGU\DUHD
&+$37(56SDUH3DUWV/LVW
$OOFRPSRQHQWVZKLFKXQGHUQRUPDORSHUDWLQJFRQGLWLRQVPD\UHTXLUHUHSODFHPHQWGXHWR
GHVWUXFWLRQZHDUHWFDUHQRWHGLQDVHSDUDWHVSDUHSDUWVOLVWIRUWKHIROORZLQJW\SHRI
HTXLSPHQW
x 'RXEOH$FWLQJ+\GUDXOLF5HWULHYHU
x 6LQJOH,VRODWLRQ6HUYLFH9DOYH
x 'RXEOH,VRODWLRQ6HUYLFH9DOYH
x 0DQXDOKDQGRSHUDWHG+\GUDXOLF3XPS
x $LUGULYHQ+\GUDXOLF3XPS
7KHVSDUHSDUWVOLVWVLQFOXGH
x GHVFULSWLRQZLWKPDWHULDOVSHFLILFDWLRQLIDSSOLFDEOH
x 0HWDO6DPSOHV3DUW1R
0HWDO6DPSOHVZLOOQRUPDOO\KDYHDOOUHFRPPHQGHGVSDUHSDUWVLQVWRFN
'RXEOH$FWLQJ+\GUDXOLF5HWULHYHU
8QGHUQRUPDORSHUDWLQJFRQGLWLRQVWKHIROORZLQJVSDUHSDUWVDUHVXIILFLHQWWRNHHSWKH
'RXEOH$FWLQJ5HWULHYHULQJRRGRSHUDWLQJFRQGLWLRQ
,WHP 6SDUHSDUW 3DUW1R 0DWHULDO
6HDO.LWIRU'RXEOH$FWLQJ+\GUDXOLF5HWULHYHU .5 9LWRQ37)(
5HSDLU.LWIRU'RXEOH$FWLQJ+\GUDXOLF5HWULHYHU &06
9LWRQ37)(
&2035(66,215,1*
6($/5,1*
25,1*
25,1*[
25,1*
25,1*
25,1*
25,1*
%$&.835,1*63,5$/
:($55,1*
25,1*
%$&.835,1*63,5$/
(;7(51$/:,3(55,1*
25,1*
%$&.835,1*,'
:,3(552'785&21
25,1*
25,1*
%$&.835,1*2'
:($55,1*
O-RING -228
,WHP -5HSDLU.LW -This is in DGGitionWRWKH6HDO.LW.TKHse are theFRPSRQHQWVWKDW
typically ZLOOUHTXLUHUHSODFHPHQWDIWHUWKHUHWULHYDOWRROKDVEHHQXVHGIRUan extended
period of time. The items areDVIROORZV
&2035(66,215,1*
%/(('9$/9(36,
48,&.&283/,1*)(0$/(-1
48,&.&283/,1*0$/(-1
35(6685(*$8*( Bar
(≈ 8700 PSI)
&06±&DOO0HWDO6DPSOHV
6HUYLFH9DOYH
6LQJOH,VRODWLRQ9DOYH
8QGHUQRUPDORSHUDWLQJFRQGLWLRQVWKHIROORZLQJVSDUHSDUWVDUHVXIILFLHQWWRNHHSWKH
6LQJOH,VRODWLRQ6HUYLFH9DOYHLQJRRGRSHUDWLQJFRQGLWLRQ
25,1*[
25,1*
25,1*[
25,1*[
25,1*
25,1*
%$//6($7
0$,16($/
Item 2 - Repair Kit - This is in addition to the Seal Kit. These are the components that
typically will require replacement after the valve has been used for an extended period
of time. The items are as follows:
%$//9$/9(
1(('/(BLEED 9$/9(
6($/&$55,(5
%<3$66VALVE 67(0
3,1;
&06±&DOO0HWDO6DPSOHV
'RXEOH,VRODWLRQ9DOYH
8QGHUQRUPDORSHUDWLQJFRQGLWLRQVWKHIROORZLQJVSDUHSDUWVDUHVXIILFLHQWWRNHHSWKH
'RXEOH,VRODWLRQ6HUYLFH9DOYHLQJRRGRSHUDWLQJFRQGLWLRQ
Item 1 - Seal Kit - includes all elastomer seals and other items that are used in the
Double Isolation Valve as per list below:
25,1*[
25,1*
25,1*[
25,1*[
25,1*
25,1*
%$//6($7
0$,16($/
1RWH7KHTXDQWLW\LVWZRIRUHDFKLWHPH[FHSWIRU2ULQJ[WKDWUHPDLQRQH
,WHP5HSDLU.LWDGGWRWKH6HDO.LWWKHFRPSRQHQWVWKDWXVXDOO\ZLOOUHTXLUH
UHSODFHPHQWDIWHUWKHUHWULHYDOWRROKDVEHHQXVHGIRUDZKLOHVXFKDVEDOOYDOYH
QHHGOHYDOYHHWFDVIROORZV
1RWH7KHTXDQWLW\LVWZRIRUHDFKLWHP
Item 3 - Balls - might need replacement, if the Service Valve is used on systems with
large amounts of sand or other particles that might cause scratches or other damages to
the surface of the ball(s). Such damages might cause minor leaks when the Valve is
used on gas systems. Please note that the balls are also included in the Repair Kit.
&06±&DOO0HWDO6DPSOHV
3XPSV
0DQXDO+\GUDXOLF3XPS
8QGHUQRUPDORSHUDWLQJFRQGLWLRQVWKHIROORZLQJVSDUHSDUWVDUHVXIILFLHQWWRNHHSWKH
0DQXDO+\GUDXOLF3XPSLQJRRGRSHUDWLQJFRQGLWLRQ
$LU+\GUDXOLF3XPS
8QGHUQRUPDORSHUDWLQJFRQGLWLRQVWKHIROORZLQJVSDUHSDUWVDUHVXIILFLHQWWRNHHS
WKHAir+\GUDXOLF3XPSLQJRRGRSHUDWLQJFRQGLWLRQ
Item 1 - Repair Kit - includes all seals and other components that will usually require
replacement when the pump is to be overhauled.
NOTE: The pump manufacturer must be contacted for ordering this kit.
Item 2 and 3 - Hydraulic Hoses with Quick Couplings - shall always be replaced if there
are visible damages in the outer layer of the hose. The Quick Couplings are different on
the two hoses (to avoid the hoses from being connected incorrectly).
NOTE: Customer must state which one of the hoses they require.
&MS±&DOOMetal Samples
&+$37(5'UDZLQJV
'RXEOH$FWLQJ+\GUDXOLF5HWULHYHU
*HQHUDO$UUDQJHPHQW'UDZLQJZLWK3DUWV/LVWVHHQH[WSDJHV
&+.'
6(('(7$,/'
%<
6(('(7$,/% 6(('(7$,/&
%
$/$%$0$
5(6($5&+$1'
'(9(/230(17
6(('(7$,/$ 127(
23(5$7,1*35(6685(%$536,
0(',80,629*0,1(5$/2,/
'(6&5,37,21
5()
5() 5()
5() 5()
5() 5()
5()
5()
5()
5() 5()
5()
5()
$ 5() 5() 5()
5() 5()
'$7(
5() 5()
'(7$,/% 5()
'(7$,/& '(7$,/'
5() '(7$,/$ 5() 6&$/(
5() 6&$/( 6&$/(
6&$/(
5(9
$/$%$0$
&UHR 72/(5$1&(681/(66
$66(0%/< 27+(5:,6(63(&,),(' &86720(5
352'8&76,1&
%<
6(('(7$,/*
%
6(('(7$,/)
$/$%$0$
5(6($5&+$1'
'(9(/230(17
6(('(7$,/( '(7$,/*
6&$/( '(7$,/+
6&$/(
'(6&5,37,21
6(('(7$,/+
'$7(
'(7$,/(
6&$/(
'(7$,/)
6&$/(
5(9
$/$%$0$
&UHR 72/(5$1&(681/(66
$66(0%/< 27+(5:,6(63(&,),(' &86720(5
352'8&76,1&
&UHR 72/(5$1&(681/(66
$66(0%/< 27+(5:,6(63(&,),(' &86720(5
352'8&76,1&
&+.'
%<
%
$/$%$0$
5(6($5&+$1'
'(9(/230(17
Tr 85x5
'(6&5,37,21
$
'$7(
3"-5-ACME
5(9
72/(5$1&(681/(66
63(&,$/7<
':*7<3( 3/$&( 3/$&( 3/$&( 3/$&( )5$&7,216 $1*/(6 '5$:1%< '$7( 0(7$/6$03/(6 6&$/( 6+712 72712 ':*12 5(9
5 ' '(* 0$: $63, 0'%
7+,6'2&80(17,1&/8',1*7+(,1)250$7,21+(5(,1,635235,(7$5<3523(57<$1'0$<127%(5(352'8&('25&23,(',1:+2/(25,13$571250$<,7%()851,6+('72 0(7$/6$03/(65'081)25'$/
27+(56:,7+287(;35(66:5,77(1&216(171250$<,7%(86(',1$1<:$<7+$7,6250$<%(+$50)8/727+(,668,1*&203$1<7+,635,170867%(5(7851('83215(48(67 ZZZDOVSLFRP LQIR#DOVSLFRP 3+21()$;
0'%%,//2)0$7(5,$/6
&+.'
$
'$7(
5(9
72/(5$1&(681/(66
63(&,$/7<
':*7<3( 3/$&( 3/$&( 3/$&( 3/$&( )5$&7,216 $1*/(6 '5$:1%< '$7( 0(7$/6$03/(6 6&$/( 6+712 72712 ':*12 5(9
5 ' '(* 0$: $63, 0'%
7+,6'2&80(17,1&/8',1*7+(,1)250$7,21+(5(,1,635235,(7$5<3523(57<$1'0$<127%(5(352'8&('25&23,(',1:+2/(25,13$571250$<,7%()851,6+('72 0(7$/6$03/(65'081)25'$/
27+(56:,7+287(;35(66:5,77(1&216(171250$<,7%(86(',1$1<:$<7+$7,6250$<%(+$50)8/727+(,668,1*&203$1<7+,635,170867%(5(7851('83215(48(67 ZZZDOVSLFRP LQIR#DOVSLFRP 3+21()$;
&+$37(56HTXHQFHRI2SHUDWLRQV
'28%/($&7,1*+<'5$8/,&5(75,(9(5722/
35(/,0,1$5<35(&$87,216
&KHFNLIPDLQWHQDQFHRIUHWULHYDOWRROVHUYLFHYDOYHDQGSXPSKDVEHHQSURSHUO\FDUULHG
RXW0DNHDWULDOLQWKHZRUNVKRSWRHQVXUHWKDWDOOSDUWVDUHLQJRRGZRUNLQJFRQGLWLRQV
&KHFNWKHWKUHDGVE\VFUHZLQJWKHVHUYLFHYDOYHRQWRWKHUHWULHYDOWRRO RQWRWKHDFFHVV
ILWWLQJ
&KHFNWKHRLOOHYHOLQWKHSXPS7KHTXDQWLW\RIK\GUDXOLFRLOLQWKHSXPSDQGLQWKHUHWULHYDO
WRROPXVWQRWH[FHHGWKHTXDQWLW\UHTXLUHGDQGLQGLFDWHGLQWKHPDQXDORIWKHSXPS
&KHFNWKDWWKHOLQHSUHVVXUHLVFRPSDWLEOHZLWKWKHRQHLQGLFDWHGLQWKLVPDQXDO
&KHFNWKHGLPHQVLRQsRIWKHSUREHthat is intended to be UHWULHYHdWRHQVXUHWKDWWKH
UHWULHYHUPRGHOLVVXLWDEOH IRURSHUDWLRQV
5(75,(9$/23(5$7,216
1. 5HPRYHWKHFRYHUVORZO\,IDQ\OHDNVRFFXUUHWLJKWHQWKHFRYHU7KHQFKHFNWRVHHLI
WKHORFNLQJSLQVDQGRULQJVDUHFOHDQDQGWLJKWHQHGSURSHUO\7KHQUHSHDWWKHRSHUDWLRQ,I
OHDNVSHUVLVWVWKHQUHWLJKWHQWKHFRYHUDQGZDLWXQWLOWKHV\VWHPLVVKXWGRZQWRUHWULHYH
2. &RQQHFWKRVHVIURPSXPSWRUHWULHYHU
3. 2SHQWKHUHWULHYHUKHDGYDOYH
4. 6HWSXPSWRLQVWDOODQGSXPSXQWLOFRQQHFWLQJURGLVIXOO\H[WHQGHGDQGSUHVVXUHUHDFKHV
DSSUR[SVLEDUVHHSUHVVXUHJDXJHRQWKHSXPS
5. &ORVHUHWULHYHUKHDGYDOYHDQGGLVFRQQHFWWKHKRVHVIURPWKHUHWULHYHU
6. 0DNHVXUHWKDWWKHRULQJDWERWWRPRIVHUYLFHYDOYHLVLQJRRGFRQGLWLRQV
7. 6FUHZWKHVHUYLFHYDOYHRQWKHDFFHVVILWWLQJDQGHQVXUHWKDWWKHVHUYLFHYDOYHLVLQ
SURSHUSRVLWLRQDQGWKHE\SDVVLVFORVHG
8. 3ODFHWKHUHWULHYHURQWKHVHUYLFHYDOYH
9. 6FUHZWKHURGLQWRWKHSOXJE\URWDWLQJWKHUHWULHYHU
10. &RQQHFWKRVHVDQGRSHQWKHKHDGYDOYH
11. 6HWSXPSWRUHWULHYHDQGSXPSVORZO\LQRUGHUWREHDEOHWRHQJDJHDQGWLJKWHQWKH
KDPPHUQXWRQWRWKHVHUYLFHYDOYH
12. &KHFNWKDWWKHEOHHGYDOYHRIUHWULHYHULVFORVHG
13. 6HWWKHSXPSWRLQVWDOODQGSXPSWRDSSUR[SVLEDURYHUWKHOLQHSUHVVXUHDVN
FRQWUROURRPDERXWWKHOLQHSUHVVXUH
14. 5HOHDVHWKHORFNLQJSLQDFFRUGLQJWRWKHVHTXHQFHVKRZHGLQWKLVPDQXDOXQWLOWKH\
DUHIOXVKZLWKDFFHVVILWWLQJ
15. 6HWSXPSWRUHWULHYHUDQGSXPSXQWLOSUHVVXUHLVEXLOWXSLQVLGHWKHUHWULHYHUPD[
SVLEDUV,IOLQHSUHVVXUHDWOHDVWSVLEDULVVXIILFLHQWWRUHWULHYHZLWKRXW
SXPSLQJVHWWKHSXPSWRQHXWUDORSHQWKHUHWULHYHUKHDGYDOYHVORZO\DQGZDLWXQWLOWKH
SUHVVXUHLQWKHSXPSLV$WWKLVSRLQWWKHSUHVVXUHJDXJHRIWKHUHWULHYHUPXVWLQGLFDWH
WKHVDPHOLQH SUHVVXUH
16. &ORVHWKHVHUYLFHYDOYH
17. 5HOHDVHWKHSUHVVXUHZLWKWKHUHWULHYHUYDOYHEOHHGYDOYH
18. /RRVHQWKHKDPPHUQXW7KHQXQVFUHZWKHUHWULHYHUIURPVHUYLFHYDOYH
19. 3ODFHWKHUHWULHYHUZLWKRSHQLQJXSDQGVHWWKHSXPSWRLQVWDOO
20. 3XPSXQWLOWKHSUREHSOXJDUHRXW
21. 8QVFUHZSUREHSOXJIURPURG
22. &KDQJHFRUURVLRQSUREHFRXSRQDQGFDUU\RXWPDLQWHQDQFHFKDQJHSULPDU\SDFNLQJ
DQGLIQHHGHGZHDUULQJV
,167$//$7,2123(5$7,21
1. &RQQHFWWKHUHWULHYHUWRWKHSXPS
2. 6HWWKHSXPSWRLQVWDOODQGSXPSXQWLOWKHURGLVH[WHQGHG
3. 0RXQWWKHSOXJSUREHWRWKHURG
4. 6HWSXPSWR"UHWULHYH"DQGSXPSXQWLOWKHSUREHLVUHWUDFWHGLQWRWKHUHWULHYHU
5. 6FUHZWKHUHWULHYHUWRWKHVHUYLFHYDOYHDQGWLJKWHQWKHKaPPHUQXW
6. 2SHQ theby-pass valveWREDODQFHWKHSUHVVXUH
7. 2SHQWKHVHUYLFHYDOYHDQGWKHQFORVHWKHE\SDVV
8. 6HW SXPS WR "LQVWDOO" DQG VWDUW SXPSLQJ XQWLO WKH SOXJ VHDOV WR WKH DFFHVV ILWWLQJ
$V VRRQDVWKLVKDSSHQVWKHSUHVVXUHJDXJHRIWKHSXPSZLOOLPPHGLDWHO\MXPSWR
KLJKHU SUHVVXUHWKDQWKHOLQHSUHVVXUHFRQWLQXHSXPSLQJWRDSSUR[SVLEDU
RYHUWKH OLQHSUHVVXUH
9. 2SHQWKHEOHHGYDOYHRIUHWULHYHUDQGRUVHUYLFHYDOYHWRUHOHDVHWKHSUHVVXUHLQVLGH WKH
F\OLQGHU0DNHVXUHWKDWWKHJDXJHRIWKHUHWULHYHUVKRZV
10. 7LJKWHQWKHORFNLQJSLQV
11. /RRVHQWKHKaPPHUQXWDQGXQVFUHZLWIURP theVHUYLFHYDOYH
12. 6HWSXPSWRLQVWDOODQGSXPSXQWLOWKHFRQQHFWLQJURGLVIXOO\H[WHQGHG
13. &ORVHWKHUHWULHYHUKHDGYDOYHDQGGLVFRQQHFWKRVHVIURPUHWULHYHU
14. 8QVFUHZWKHURGIURPWKHSOXJE\URWDWLQJWKHUHWULHYHU
15. 5HPRYHWKHVHUYLFHYDOYHIURPWKHILWWLQJ
16. 6FUHZWKHSURWHFWLYHFRYHUDQGWLJKWHQZHOOJUHDVHWKHDFFHVVILWWLQJWKUHDGV