PT.

KOROSI SPECINDO
Corrosion Monitoring Systems Eng Doc. No.:KS-MNL-06-Rev0

INSTALLATION, OPERATION & MAINTENANCE

INSTRUCTIONS

TKS RP RETRIEVAL TOOL

Rev Date Prepared Approved Description

0 June/24/2004 Yudi SD Issued for approval
 KOROSI SPECINDO

SECTION I
ACCESS FITTING INSTALLATION

I. Introduction

This procedure covers the positioning Flanges and welding of the Korosi Specindo’s
Flarweld, Buttweld, Socketweld and NPT access fitting to the wall of pipe or vessel. See
fig 1.

READ THIS DOCUMENT COMPLETELY BEFORE COMMENCING

THE WORK
This procedure is operating manual for proper operate this
product only, The operator must be oblique the national safety
CAUTION procedure as a common and or other local or company regulation
as well. Something in doubt asking Korosi Specindo PT.
All instruction in this procedure does not cover any installation
procedure.

1. Proper installation and preparation for best protection the fitting

a) Orientation of the Fitting

1) Set the fitting on vertical position with the top (ACME thread end) up. Other axial
orientations may be specified for the location, consult the project documentation
before installation. Ensure that there will be adequate clearance above the fitting to
operate the retriever, as follows:

8’ (2.4 m) clearance above the top of

Pipe size from 2” – 12”
fitting. *
11’ (3.3 m) clearance above the top of
Pipe size from 24” – 36”
fitting. **

2) Set the longitudinal orientation of corrosion monitoring device, by mark across the
hex head of solid plug then install in access fitting to indicate the orientation of
corrosion monitoring device. Fluid flow must be across each corrosion-monitoring
device (this procedure not relevant for flush type coupon).

3) The clearances must be apply to all orientations.

4) A minimum lateral clearance of 9” (230 mm) is required between fitting and from
other obstructions. The dimension is from the fitting centerline, ideally a 4’ (1.2 m)
space should be allowed.

5) When the mounting is placed vertically below the line or vessel, a 4’ (1.2 m)
minimum diameter working space must be provided. The fitting to be off center 1’
(300 mm) from the edge of the area at the closest bottom point and 3’ (1 m) at the
farthest point.

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Fig.1. Access Fitting

b) Installation Flanges

When install the flanges, the correct sequence for fasten flange bolts must be as
shown in fig. 2. First, it will provide the best surface contact
1 between sealing gasket to each flanges face by hand tight, then
5 8 firmly tighten the bolts in sequence as above.

3 Note: “Hot Flow” of gasket material may occur on operating

3 4
conditions. It will resulting loss of bolts pressure. Bolts must be
retightened after operating temperature has been reached.
7 7 6
2 2

Fig.2. Flange Bolts

B. Welding of Korosi Specindo Access Fitting

a. Safety Considerations
Every welding process must be control by supervisor, who will responsible to any
tasks as follows:

1. Determine contents of the system. Hot work on lines or vessels containing

corrosive or toxic materials should be given special consideration. Certain
materials may cause metallurgical or chemical changes in the heat zone.
Example, carbon steel is changed metallurgically at elevated temperatures in the
presence of caustic or elemental sulfur. Welding should never be performed on
equipment which is operating above its rated working pressure and temperature,

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nor on equipment which is operating at less than atmospheric pressure; such as,
in a vacuum.
2. Determine if air is present, especially combination of vapors in equipment. The
oxygen content should be, and should remain at a level, which precludes the
formation of a flammables mixture. Heating compressed air lines or vessels may
cause detonation. Example, if lubricating oil has been vaporized and distributed
throughout the system by a compressor. Pipeline or vessels subject to this
possibility usually can be removed or isolated from service and purged prior to
hot work.
3. Determine if the equipment is metallurgically suitable for welding. Example,
hydrogen embrittlement or attack would make it impossible to complete the weld.
Some steels and thickness require stress relieving, special treatment is required
for high tensile alloy steels and special welding rods must be used.
4. Determine conditions, under which welding may be done and establish a safe
procedure. The job should be inspected by individual responsible for authoring
the welding operations. Before granting authorization to proceed, the responsible
supervisor should indicate definite safety precautions to be followed. A test of the
hot work area for flammables gas presence may be desirable or required. An
inspection of the parent metal is a necessity.

5. Observe the operation, to make sure the foregoing conditions are followed
during performance of the job operation.

6. If hot tapping, determine the capabilities of the hot tapping machine. Hot tapping
tools are limited to use within their pressure and temperature ratings.

b. Preliminary Job Considerations

In additions to safety considerations under which welding or hot tapping is to be
done, the responsible supervisor in charge must be:

1. Ensure the correct equipment or line has been selected to be welded or hot
tapped.

2. Obtain the necessary clearance or approvals.

3. Provide either a suitable fire extinguisher (dry chemical) and/or a pressurized fire
hose.

4. Determine by visual inspection, hammer testing, ultrasonic thickness measuring

devices, radiography (X -ray), or other approved thickness measuring devices
that the equipment to be welded or hot tapping is sufficient for strength and
thickness to receive the connection, a wall thickness is define by actual pressure
and corrosion allowance of pipe material. Previous inspection records and data
on corrosion rates will be useful in making this determination.

5. Determine if preheating is required. Studies have indicated that most steels

should be preheated prior to welding (stainless steels with due to moderate heat)
when the fluid or metal temperature is less than 50 oF (10 o C).

6. Determine the proper fitting for use in making the connection. Korosi
recommended use a Flarweld or Buttweld. Cause they only require only one

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weld, thus reducing the changes of distortion and warpage. Also more efficient in
time and money.

7. Design the connection, according to the proper code ASME Boiler and Pressure
Vessel Code or API Standard 650, Welded Steel Tanks for oil storage.

c. Protection Access Fitting during Welding

1. The Korosi Specindo plug must be removed from the fitting during welding and
stress relieving operations. The body must be inspected to ensure that there has
been no damage to the external Acme thread, the upper shoulder and lip of the
fitting, the internal thread or internal seal shoulder during its shipment. If damage
is found the fitting must be replaced.

2. The external Acme thread and upper shoulder of the fitting must be protected
from weld spatter during welding. Wrap heat resistance cloth around the external
Acme thread and stuff the bore of the fitting with a retrievable wad of heat
resistant material to a point just below the internal seat. This is to prevent weld
spatter onto thread and seal areas.

3. The internal thread and internal bore below and the internal shoulder must be
protected from weld spatter during welding.

4. The welding procedure should be designed so that the upper portion of the fitting
temperature does not exceed 1000 oF (540 oC) during welding. Higher
temperatures encountered during stress relieving are acceptable.

Welding procedures are the final responsibility of the

Notice user’s engineering authority and must be approved prior
to use.

d. Welding Process

1. Select welding rods appropriate to the fitting and line material.

2. Weld Gap, Korosi Specindo Access Fitting body or connecting fitting must be
raised off the surface of the pipe or vessel wall to establish a proper weld gap.
This can be done by placing four (4 ea) 1/16” (1.6 mm) spacers or rods under the
fitting to provide the proper gap between the curvature of the pipeline or surface
of the pressure vessel wall and root or base of the fitting. Normal weld gap is
1/16” (1.6 mm) per ANSI B31.1. 1973.

3. Arc welding should be used if at all possible for all grades and types of steel.
Because this will minimize warpage and distortion of the Access Fitting body
cause of its localization of concentrated heat. Care should be exercised so that
the body is properly positioned to prevent misalignment of the hot tapping tool is
used at a right angle or perpendicular to the work area. Also, avoid excessive
arcing because arc spots on the body can cause stress and consequently body
warpage while cooling. Recommended procedures for welding and special hole
cutting considerations for various metals as follow:

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a. Carbon Steel

1) Tack Weld. Preheat the fitting to 600 oF (315 oC). Tack welds the fitting to
the line between the spacers using 3 mm (1/8”) welding rods. Remove the
spacers and weld slag from the tack welds.

2) Stringer Bead. Apply a stringer bead completely around the base of the
fitting using 3 mm (1/8”) diameter rod for 3 mm maximum layer. Remove
weld slag.

3) Cover Beads. Apply continuous cover beads to fill the bevel and provide a
smooth tapered weld.

b. Stainless Steel

Do not preheat!, otherwise; use the same procedure as shown for carbon
steel with the following considerations:

1) In the hole cutting procedure, a hollow drill or drill bit should be used to cut
small size openings. Abrasive cutting wheels are generally used to make
larger sized holes.

2) Arc cutting or injections of iron powder into an acetylene flame are other
methods used. If however, any of these flame or arc method are used, the
hole should be cut under size ¼” (6.5 mm) on the diameter to allow for
removing the heat affected areas by grinding before welding.

3) Either the heli-arc (electric arc) or metallic (TIG and MIG) methods may be
use for welding. The sequence of welding passes for both alloy and
stainless is the same as outlined for carbon steel.

e. Post Welding Inspection

After welding the following procedures must be followed:

1. The post-heat and cooling period must be in accordance with relevant welding
procedures and engineering standards.

Do not install a solid or hollow plug into access fitting if the

CAUTION fitting still hot. It cause primary packing and o-ring melting,
cause stacking onto its internal surface.

2. Inspect the external ACME thread to ensure it is free from weld spatter. If there is
any weld spatter it must be carefully removed by chipping and filing.

3. Inspect internal (UNF) thread, internal bore above seat and internal seat to
ensure it is free from weld spatter. If there is any weld spatter it is recommended
to use a thread tap assembly to repair/clean the threads or use a seat reamer for
reaming the bore and seat.

4. Inspect the internal bore of the body below the seat, the interior surface of the
weld area and the internal surface of the hole through the pipe or vessel wall.
These surfaces shall be ground or reamed as necessary to ensure a full ID of
1.377” (35.00 mm). Care must be taken to eliminate any damage to the internal
thread, bore and shoulder during grinding operations.

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5. A hydrostatic test must be carried out. (Normally 1-1/2 time line pressure)

6. On completion of the inspection and after any subsequent stress relieving a

Korosi Specindo plug assembly must be screwed into the access fitting and fully
seated. The plug must be capable of insertion and full seating so that the top
shoulder of plug (below the hex nut) is flush with top lip of the fitting (15 turns
(360o ) of plug), If the plug is tight, the fitting may have been distorted during the
welding process and the internal threads must be chased with the correct thread
chaser. After chasing, if the plug still cannot be inserted easily, the fitting must be
blanked – off and a new access fitting point installed at another point.

f. General

1. When the installation has been completed and a hollow plug is to be installed,
the probe or bore-sealing nut provides the pressure barrier. The use of a
stainless steel ½” NPT plug is not recommended.

2. To determine the condition of the access fitting, periodic inspection must be

performed. When under pressure, Ultra-Sonic and X-ray testing can be used. If
shut down is possible, caliper can be used. If, after inspection it is considered
that the access fitting must be blanked – off and a new access point installed at
another point.

C. Access Fitting Maintenance

The interval time maintenance of Access Fitting is the same time of scheduling time for
remove – replace corrosion monitoring devices. Base on NACE RP 0775-99. 3.5 for
exposure time have been classified into Short term (1-45 days) and Long term (1-90
days). Access maintenance consists of:

1. Cleaning and repair internal threads (UNF) by using a Thread Tap Assembly
(refer to section III. 3.6 Special Procedures for Access Fitting).

2. Cleaning internal threads (UNF) by using a thread brush (refer to section III. 3.6
Special Procedures for Access Fitting)
3. Grease external thread (ACME)
4. Check access fitting face up end (O-ring seat Protective cover) for scratch, use a
smooth sand paper and bastard to repair.

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SECTION II
CORROSION COUPON HANDLING
I. Introduction
This practice covers procedures for preparation, analysis and interpretation of
Corrosion Coupons in Oilfield Operation.

II. Equipment
 Analytical balance with accuracy ± 0.1 mgr
 Depth gauge
 Microscope
 Pitting Gauge
 AAS / ICP
 Titrator
 Glass Ware
 Digestion Sampler

III. Operation
3.1 During Installation

Preparation
 Prepare coupon for corrosion testing.
 Coupon should be new.
 Do not re-used coupons after exposure and analysis.
 Choose the method preparation of the metal

1. Open the envelope and take out coupon carefully. Avoid contamination of
coupon caused by contact with other materials, oil or chemicals.

2. Record the following information:

- Coupon serial number.
- Installation date.
- Name of system.
- Location of the coupon in the system (including fluid or vapor phase),
name of the platform, sketches the position of the coupon in the pipeline
(put all data on the Envelope), or take a picture of that location.
- See the typical corrosion coupon report from Envelope & Appendix A

3. Record the physical condition of pipeline such as:

- Dimension of pipeline,
- Fluid / water temperature,
- Pressure,
- Density,
- Viscosity
- Flow rate.

Number Dimension
Number of Type of
of of Pressure Density Viscosity Flow Rate
Pipeline Fluid
Platform Pipeline

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3.2 During Removal

1. Remove the coupon out of the system carefully.

2. Record the following items:
- Coupon serial number
- Removal date
- Observation of any erosion or mechanical damage
- Appearance of scale
- Appearance of corrosion product
- The coupon should be photograph immediately after removal,
particularly if appearance of the corrosion product or scale is
important.
3. Record any changes of fluid flow rate during exposure time:
- Any other pertinent data such as shut in time
- Changes in velocity and inhibitor treatment,
- Type or materials for corrosion inhibitor,
- Dosing rate and dosing time of corrosion inhibitor,
- Position injection chemical in the pipeline should also be recorded.
4. Put the coupon into original envelope carefully and seal it (Avoid
contamination!)
- Send the coupon immediately to laboratory for analysis.
- Do not remove any scale or corrosion product in the field.

Appearance
Coupon Observation Date Report
Removal of scale & Date of
Serial Mechanical of Send to of
Date corrosion Photograph
Number Damage Laboratory Analysis
product

Note : Coupon must not be handled with the bare hand, and
maximum cleanliness must be maintained during installation
and removal process. The use of surgical or rubber glove is
recommended while handling coupons.

3.3 Exposure Time

Exposure time must be considered when interpreting corrosion coupon data.

Short-term exposure (15 to 45 days) provides quick answer but may give
higher corrosion rate than long-term exposures. Aggravating conditions, such
as bacterial fouling, may take time to develop on the coupon. Short exposure
times may be advantageous when evaluating inhibitor effectiveness. Longer
exposures (60 to 90 days) are often required to detect and define pitting attack.
Because exposure time affects test results, exposure periods should be as
consistent as practical. Tolerance of 7% allows a variation of 2 days on 30
days exposure. This is satisfactory for most applications.

IV. Storage Maintenance

Corrosion coupon should be storage in a clean, dry and warm (25 oC – 32 oC max)
area. The coupon storage area should not be placed in that could increase
humidity. Normal life time for coupon after shipment date is approx. 1 year, for best
result after 1 year storage coupon should be blasting.

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SECTION II
RETRIEVAL TOOLS
I. Introduction

This practice covers procedures for preparation, process of installation – removal and
safety consideration during retrieval any corrosion coupon and probe.

The retrieval tool TKS RP and service valve can be used to insert or retrieve corrosion
monitoring devices from process systems operating under full pressure (up to 6000 psi or
413 Bar). Also can be used to retrieve a variety of sensors from either the MHTM high
pressure access system or any conventional 2-inch access system.

The tool is constructed to comply with NACE MR-0175 and is pressure tested at the
factory for a working pressure of 7800 psi (537 Bar). The standard tool and service valve
are suitable for operation between -4˚F and 450˚F (-20˚C and 232˚C), both version of the
retriever tool and valve use carbon steel construction of the hammer nut.

Stroke
Item Description
14” 18” 25” 37” 49”
A Retriever Tool Overall Length - inches 39 47 63 91 111
Retrieval Tool and Service Valve
B Overall Length to Pipe OD (include 54 62 78 106 126
non-tee access fitting) - inches
Stroke Available – inches 18.5 22.5 30.5 44.5 54.5
Retrieval Tool Weight - lbs 47 52 62 83 97
C Case / Tool Kit Weight - lbs 37 37 40 48 53
Total Weight - lbs 84 89 102 131 150
Total Cubage - ft3 2.4 2.4 2.9 4.3 4.8
Max. Holder length – inches 5 9 17 31 41
D
Max. Probe length – inches 4 8 16 30 40

II. Safety

a. Test and check should be done to all equipment before attempting to use in field.
b. Safe operation requires minimum 2-trained operator.
c. Do not use this retrieval equipment unless you have been trained in its safe operation.
d. Make sure you have complied with all plant safety requirements and environmental
regulations.
e. Identify the type media its pressure and temperature. Review material safety data
information on the media prior to operation.
f. Ensure you have all the required safety equipment and used, i.e.: protective clothing,
safety helmet, safety glasses, safety gloves, ear plug, safety shoes and breathing
apparatus when toxic atmosphere exists.
g. 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.
h. Insure you have enough clearance for safe operation; there must be sufficient space
available for head room as well as enough shoulder room to allow free movement of
the equipment as well as of the operator. Clearance beyond the top of the access
fitting body is required for movement and installation of the retriever and service valve.

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For shoulder room above ground level requires 3 feet radius circle and below ground
level a minimum diameter of 4 feet is required with the fitting located off to one side of
the hole.
Note: Wind direction prior to starting operations involving hazardous
products. The Use of Diverter Hose Assembly is recommended.
i. Ensure you have scaffolding if the Access fitting that to be serviced is mounted above
the operator.

III. Operation

3.1 Preparation
Note:
- Ensure by-pass service valve / ball (12) in “OPEN” position.
- Ensure bleed valve retriever (6A) and service valve (22) in “CLOSE” position.

a. Check condition of service valve.

Inspect the O-ring (18) at the hammer nut end (2) for nicks, cuts and abrading

b. Check condition of retriever.

Rotate the retriever handwheel (11) clockwise and counterclockwise to ensure
it’s lubricated and operating properly; check all the thread connection parts & O-
ring especially O-ring (37) at thread adapter for nicks, cuts and abrading.

c. Check pressure in pressure gauge on protective cover.

Note: If there’s any indication pressure, release by opening bleed valve in
protective cover.

3.2 Removing Procedure

1. Remove the access fitting cover (protective cover) by using a spanner
wrench (“C” pin wrench).

2. Remove the pipe plug ½” NPT (1). Use a crescent wrench to remove pipe plug
slightly counterclockwise.

: If for any reason there’s pressure behind the plug, after one or
Warning
two minutes has not been bleed – 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 plug and following the
procedure of overshoot adapter.

3. Connect the service valve to the fitting. Lift the service valve and place it on
the access fitting body. Turn the hammer nut (20) clockwise until the service
valve is securely seated. Tap the hammer nut (20) tight using a brass hammer.
The valve should be in full “OPEN” position.

4. The retrieval tool handwheel (11) should be at its stop in the full, run-out position,
secured there by the lock-pin (10) placed in one of the lock holes on the inner
diameter of the handwheel.

5. Install the retrieval tool on the open service valve. CAUTION: See chapter 3.2.13
for systems greater than 2000 psi.

6. With one hand on the retrieval tool handwheel, use the other to remove the
handwheel lock-pin (10) and placed it in its keeper (storage) hole.

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7. Slowly rotate the handwheel (11) clockwise to move the spring (B5) loaded
socket adaptor (1B) to the plug. Slowly turn the T-bar handle (28) clockwise until
it comes in contact with the solid plug assembly. Turn the T-bar (28) handle 3-5
turns to engage the landing screw (B1) in the plug. Check for engagement by
attempting to rotate the handwheel (11) counterclockwise. The handwheel (11)
should not rotate. If it does rotate, repeat the start of this step. With slight
clockwise pressure on the handwheel (11) turn the T-bar handle (28) in the
clockwise direction until the spring (B5) loaded socket seats on the solid plug.
With continued pressure on the handwheel (11), turn the T-bar handle (28) in the
counterclockwise direction 2-5 turns.

Note: You should notice system pressure equalizing past the plug assembly into
the retrieval tool body after approximately two (2) turns of the T-bar
handle (28).

CAUTION: Do not rotate the T-bar handle (28) more than five (5) times without
equalization occurring. If pressure does not equalize, you must have the tool
back pressured to equal or to slightly exceed system pressure to successfully
accomplish plug retrieval. Equalization may be verified by checking the pressure
gage on the retrieval tool. As you rotate the T-bar handle (28), you will notice the
handwheel (11) is rotating in the run-out direction.

8. When the handwheel (11) stops rotating, the plug assembly has reached the end
of its threads (approximately 15-16 turns). Rotate (run-out) the handwheel (11) to
its stop to retrieve the plug into the tool body.

9. Lock the handwheel (11) in the full run-out position to prevent possible damage
to the service valve or plugs should it gravitate downward.

10. Close the service valve / ball (12).

11. The retrieval tool may now be bleed down to atmospheric pressure. (See 3.2.14
for venting hazardous products). In liquid service, a bleed hose may be
connected from the tool to a container to catch the drain product. Open the
retrieval tool bleed valve(s) (6A). Leave the bleed valve(s) (6A) open. Check the
retrieval tool pressure gage (6) for zero reading.

Note: If a bleed hose is connected to the auxiliary bleed valve (6A), be certain
personnel at the discharge end are aware of the bleed-off. When the tools
is being used in liquid service, a splash pan or container having
approximately two (2) gallons (16 inch tool) capacity should be used to
contain the liquid which will drain from the tool during bleed-off.
Approximately ½ cup of liquid will remain in the tool below the bleed valve
after bleed-off. A splash pan will contain this residual product.

12. Manipulate the plug assembly out of the tool body for service or inspection.

13. Where the retrieval tool is being operated on system over 2000 psi, it is
recommended the operator back pressure the tool to equal system pressure after
installing the tool on the service valve, (see back pressure Procedure below).
Since the pressure differential across the plug is decrease, thread life in the
plug/fitting assemblies is prolonged. Torsional requirements on the spline rack
(32) are also reduced and the plug will be more easily removed.

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Back Pressure Procedure

1. To back pressure the retriever, attach the ¼” female quick connect to the
retriever bleed valve (6A). Either retriever bleed valve may be used.

Suggestion: Attach the back pressure pump hose to whichever retriever

bleed valve (6A) (quick connect) is lower so that the upper retriever bleed
valve (6A) may be used to bleed off air as the retriever is filled.

2. Connect the back pressure pump hose female quick connect to the male
quick connect.

3. Open the retriever bleed valve (6A) and pressurize the retriever to the system
pressure. Operate the back pressure pump in accordance with the Enerpac
tech manual or other pump brand manual.

Note: The back pressure pump reservoir may need to be filled several times to
completely fill the retriever.

4. Pressurize the retriever to slightly less than system pressure. Shut the
retriever bleed valve, depressurize the back pressure pump, and remove the
pump from the retriever.

5. Return to step 6.

14. An optional diverter hose assembly is recommended when bleeding off retriever
pressure; fluids can be collected in a container or diverter 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 (P/N.
TKS-A-DH) assemblies are:
Diverter hose assy 10 ft (3.0 m)
Diverter hose assy 25 ft (7.6 m)
Diverter hose assy 50 ft (15.2 m)

3.3 Fitting Corrosion Coupon Holders and Coupons

1. Unscrew and remove the solid plug (2) from the socket adapter pilot (B1).

2. Unscrew and remove the corrosion coupon (7) from the coupon holders (5).
See section I for handling of coupon.

3. Slack off the anti-vibration set screw (8) using a hex key.

4. Remove coupon holder (5) from the bottom of the solid plug (2) (left hand
thread). Replace any used primary packing (4) and O-ring (3).

5. Replace coupon holder (5) and tighten. Use no more than one-quarter turn
against the primary packing seal.

6. Fit a new anti-vibration set screw (8) and tighten.

7. Assemble the new coupon (7) on the coupon holder (5), ensuring that the
coupon (7) are completely insulated from the mounting screw nuts (6) and

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coupon holder (5) by utilizing the insulation and mounting hardware set (6)
provided.

8. Make a mark across the hex of the solid plug (2) to indicate the orientation
of the coupon (7). Fluid flow must be across each coupon – not against the
face of the coupon (this procedure not relevant to flush type coupon).

Note : Coupon must not be handled with the bare hand, and
maximum cleanliness must be maintained until the coupons are
inserted into the pipe. The use of surgical or rubber glove is
recommended while handling coupons.

9. Replace the plug and holder assembly in the fitting as described below.

Fig 2. Corrosion Coupon Assy

3.4 Fitting Probe Insert and Hollow Plug Nut

1. Unscrew and remove the hollow plug (2) from the socket adapter pilot (B1).

2. Remove hollow plug nut (5) from bottom of hollow plug (1) if has been
installed. Replace any used primary packing (2), probe packing and set screw (3
& 4).

3. Screw the probe (6) insert into the bottom of the hollow plug (1), first
checking that a new square section probe packing seal is fitted. The probe insert
must be tightened down very firmly (left hand thread). Steps 3 & 4 also apply
when hollow plug nut (5) is fitted in place of a probe.

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4. Tighten the anti vibration set screw (3 & 4).

5. Replace the plug (1) and Probes (6) assembly in the fitting as described
below. For majority of probe there is no requirement to orientate the probe (6) in
the fluid flow. Some special probes Duo and Sand for example, require
orientation – consult the installation instructions provided with these items.
Ensure removal of all traces of moisture within the hollow plug (1) and six – pin
electrical connector. If setting an extension adapter, makes certain that the key
way is properly located before pushing the pins into the sockets.

Notice : Rotation after the pins are located into the sockets can
cause irreparable damage to the probe.

Fig.3. Corrosion Probe Assy

3.5 Installation Procedure

1. Index the plug assembly hex. If the corrosion monitoring device requires
orientating 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.

2. Apply grease (lithium base grease) to the primary packing and O-ring (solid or
hollow plug).
Note: DO NOT apply grease to the corrosion monitoring devices

3. Install the solid/hollow plug on the retrieval tool socket adapter.

4. Rotate the retrieval tool handwheel (11) counterclockwise until the plug is full
retracted into the tool body. Lock the handwheel (11) in this position by inserting
the handwheel lock-pin (10) provided into the top or bottom most lock hole on the
inner diameter of the handwheel. This will prevent the possible free downward
travel of the rack assembly, which could damage the service valve.

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5. The service valve / ball (12) should be in the “closed” position. Install the retrieval
tool on the service valve. Close the bleed valve(s) (6A) on the retrieval tool and
service valve (22).

6. With one hand on the retrieval tool handwheel handle (40), use the other hand to
remove the handwheel lock pin (10) and placed it in its keeper (storage) hole on
the handwheel.

7. Slowly open the service valve-equalizing valve (27) to pressurize the retriever.
Before proceeding further, wait until the retriever is fully pressurized.

8. Slowly open the service valve and close equalizing valve (27). An extension bar
is provided with the service valve to assist opening the valve, if necessary.
CAUTION: See 3.2.13. for systems greater than 2000 psi.

9. Rotate the handwheel (11) clockwise (run-in-direction) to move the plug

assembly down the tool body and through the service valve until it makes light
contact with the access fitting.

10. Apply slight clockwise pressure on the handwheel (11) while turning the T-bar
handle (28). This will locate the spring (B5) loaded socket (B1) onto the hex of
the plug assembly. With the adaptor engaged in the plug assembly, continue
turning the T-bar handle (28) clockwise (approximately 15 turns) until a definite,
positive stop is felt. This is your indication that the plug has seated. Do not over
stress the rack assembly by applying unnecessary rotational force on the T-bar
handle (28).

Note: An alignment mark may be placed on the T-bar handle (28) drive ring to
assure that the device is in the proper alignment with the pipe flow.

11. The retrieval tool may be bleed down to atmospheric pressure. (See 3.2.14 for
the venting of hazardous products).

CAUTION: If after approximately 1 minute, product continues to vent through the

bleed valve, the seal on the plug assembly may not be seated or may be
damage. Close the bleed valve (6A), rotate the T-bar handle (28)
counterclockwise 1/8 turn and then clockwise 1/8 turn to its original position.
Reopen the bleed valve (28). If product continues bleeding from the bleed valve
port, remove the plug assembly and check the plug seal for damage. (See 3.6.
Special Procedures for Access Fitting).

Note: If a bleed hose is connected to the auxiliary bleed valve, be certain

personnel at the discharge end are aware of the bleed-off. When the tools
is being used in liquid service, a splash pan or container having
approximately two (2) gallons (16 inch tool) capacity should be used to
contain the liquid which will drain from the tool during bleed-off.
Approximately ½ cup of liquid will remain in the tool below the bleed valve
after bleed-off, if the access fitting is mounted in a “12 o’clock” position.
This may be bleed-off using the bleed valve on the service valve.

12. Holding counterclockwise pressure on the handwheel (11), turn the T-bar handle
(28) in the counterclockwise direction until the spring (B5) loaded socket adaptor
has cleared the plug assembly.

IOM RETRIEVER TKS RP 15

 KOROSI SPECINDO

Note: Monitor the bleed valve (6A) for any discharge. If discharge occurs, stop
rotating the T-bar handle (28). Attempt to reseat the plug by putting
clockwise pressure on the handwheel (11) and turning the T-bar handle
(28) in the clockwise direction. Once the plug is reseated, attempt step 9
again.

13. Turn the handwheel (11) in the counterclockwise direction until the adaptor is
fully retracted in the tool body.

14. Secure the handwheel (11) in position by removing the lock-pin (10) from its
keeper hole and placing it into the lock holes on the inner diameter of the
handwheel.

15. Verify that there’s no pressure in the tool body by checking that the bleed
valve(s) is in the open position. There should be on pressure indication on the
retrieval tool pressure gage at this time.

16. Remove the retrieval tool from the service valve. Check for splash pan in liquid
service.

17. Remove the service valve from the access fitting. Check for splash pan in liquid
service. If installing electrical devices, dry the plug assembly before installing
protective cover.

18. Install protective cover on the fitting. Close optional bleed valve on the protective
cover.

Note: The retrieval tool and service valve should be cleaned after each day’s
use with solvent, diesel fuel or hot, soapy water. The tool should be
disassembled, cleaned, and inspected after each 50 cycles
(approximately) or prior to storage. (See chapter IV. Retrieval Tool
Maintenance)

3.6 Special Procedures for Access Fitting

Retriever and service valve may also be used with appropriate special tools to either
repair or aid in cleaning the access fitting body while operating on lines that are
under system pressure.
When using the service tools described within this section, it is advisable to use the
shortest stroke, lightest retriever available, it will provide the better operational
sensitivity.

IMPORTANT: The following procedures assume that the service valve is still
installed on the access fitting body. It is in the closed position and
the plug assembly is absent from the access fitting body.

A. Thread tap service

The thread tap service is used to clean up product scale, chips from threads after
hot tapping or to repair thread damage caused by cross threading in the plug
assembly or by galling.

1. Attach and grease the tap. Attach the tool to the socket adapter pilot thread
(1B). Protect hands while applying grease liberally to the cutting edges.

2. Connect the retriever. Lift the retriever and place it on the service valve. Turn
the hammer nut (2) clockwise until retriever is securely seated tightened in

IOM RETRIEVER TKS RP 16

 KOROSI SPECINDO

place on the service valve. Use a brass hammer to make up a secure

connection.

3. Open the service valve by-pass then open service valve ball (12).
CAUTION: See 3.2.13 for systems greater than 2000 psi.

4. Rotate the handwheel (11) clockwise (run-in-direction) to move the thread tap
assembly down the tool body and through the service valve until it makes
light contact with the access fitting.

5. Rotate clockwise the handwheel (11) while turning the T-bar handle (28).
Continue turning the T-bar handle clockwise (approximately 14-16 turns),
occasionally turn the T-bar handle counter clockwise to help the tap threads
to clear scale or chips from the tool flutes.

WARNING : DO NOT turn T-bar handle clockwise more than 16

turns; it makes damaged the inside of Access
Fitting.

6. Rotate counter clockwise T-bar (28) for about 14-16 turns until the tool
threads are disengaged from the internal threads access fitting. Rotate (run-
out) the handwheel (11) to its stop the thread tap into the tool body.

7. Lock the handwheel (11) in the full run-out position to prevent possible
damage to the service valve or plugs should it gravitate downward.

8. When the tap operation is completed, connect the diverter hose assembly to
the retriever bleed valve (6A). Open the retriever bleed valve (6A) and allow
bleed – Off for approximately twenty second. Normally this is sufficient time
for debris to be flushed from the access fitting body threads.

9. Close the retriever bleed valve (6A). Remove the diverter hose assembly.

10. Close the service valve (ball) (12) and the service valve bleed screw (22).

11. Bleed and remove the retriever. Open the retriever bleed valve (6A) and
allow pressure to bleed off completely. Using the brass hammer, tap loose
and fully unscrew the retriever hammer nut (2). Lift the retriever from the
service valve.

12. Remove the tap. Unscrew the tap from the socket adapter pilot (B1).

Note: if the tool flutes have a large amount of debris, it is recommended that
the thread brush service assembly be used to clean the access fitting
body and threads prior to reinstalling the plug assembly.

B. Thread brush service

The thread brush service assembly is used to clean small amounts of debris
from the access fitting threads.

1. Attach the thread brush service assembly to the socket adapter pilot threads
(B1).

IOM RETRIEVER TKS RP 17

 KOROSI SPECINDO

2. Connect the retriever. Lift the retriever and place it on the service valve. Turn
the hammer nut (2) clockwise until retriever is securely seated tightened. Use
a brass hammer to make up a secure connection.

3. Open the service valve by-pass then open service valve ball (12).
CAUTION: See 3.2.13 for systems greater than 2000 psi.

4. Rotate the handwheel (11) clockwise (run-in-direction) to move the brush

assembly down the tool body and through the service valve until it makes
light contact with the access fitting.

5. Brush the threads, turning T-bar handle in (28) a clockwise direction, until it
bottom. While the other hand rotate the handwheel to move down the brush
tool.

Warning : Do not turn the brush counterclockwise

6. Rotate handwheel (11) counterclockwise direction until the brush tool is fully
retraced in the tool body.

7. Lock the handwheel (11) in the full run-out position to prevent possible
damage to the service valve or plugs should it gravitate downward.

8. When the cleaning operation is completed, connect the diverter hose

assembly to the retriever bleed valve (6A). Open the retriever bleed valve
(6A) and allow bleed – Off for approximately twenty second. Normally this is
sufficient time for debris to be flushed from the access fitting body threads.

9. Close the retriever bleed valve (6A). Remove the diverter hose assembly.

10. Close the service valve ball (12) and the service valve bleed screw (22).

11. Bleed and remove the retriever. Open the retriever bleed valve (6A) and
allow pressure to bleed off completely. Using the brass hammer, tap loose
and fully unscrew the retriever hammer nut (2). Lift the retriever from the
service valve.

12. Remove the brush service assembly. Unscrew the tool from the socket
adapter pilot (B1).

C. Surge Tube Assembly

The surge tube assembly is used to clean small amounts of debris from the
access fitting body threads. Follow the below procedures to use it.

1. Connect the surge tube assembly to service valve.

a) Close the surge tube bleed valve (6A).
b) Place hammer nut (2) end of the surge tube assembly on the service
valve. Turn the hammer nut (2) clockwise until the surge tube assembly is
securely seated.

2. Connect diverter hose/high pressure tubing to surge tube bleed valve (6A).

3. Clean the access fitting body.

a) If the lines pressure is low (pressure lower than 250 psi – 17 bar)
 Open the service valve quickly

IOM RETRIEVER TKS RP 18

 KOROSI SPECINDO

 Open the surge tube bleed valve (6A) and allow for approximately
twenty seconds.
 Close the surge tube bleed valve.
 Close the service valve.
 Open the surge tube bleed and allow the surge tube pressure to bleed
off.
 Closes the bleed valve (6A) of surge tubes then remove the diverter
hose/high pressure tubing.
 Repeat the step a. through f. at least two more times.

b) If the lines pressure is high (pressure higher than 250 psi – 17 barg)
 Open the equalizing valve (27) of service valve; watch the pressure
inside the pressure gauge (6B). By opening the equalizing valve (27)
the torque required to open the service valve ball (12) would reduce.
 When the pressure inside the surge tube assembly is 17 bar below the
line pressure open the service valve quickly.
 Open the surge tube bleed valve (6A) for approximately twenty
seconds.
 Close and open the surge tube bleed valve (6A) at least two more times
and each times allow for approximately twenty seconds. Each time the
surge tube bleed valve (6A) is open, partially close then fully opens the
service valve to remove the solids/debris from the seat area.
 Close all valves. Close the surge tube bleed valve (6A), the service
valve (22) and then equalizing valve (27).
 Open the surge tube bleed valve (6A) and allow the surge tube
pressure to completely bleed off.
 Close the surge tubes bleeds valves (6A) then remove the diverter
hose/high pressure tubing.

4. Remove the surge tube assembly

Tap looses and fully unscrews the surge tube hammer nut (2). Lift the surge
tube assembly from the service valve.

D. Steel Pipe Plug Adapter

The steel pipe plug adapter is used to install or allow retrieval of the ½”, if the
plug assemblies are under pressure. This tool is used in cases where bleed – off
cannot be plug.
The following procedure assumes that the service valve not to be installed and
the plug assembly are present within the access fitting body. If the service valve
is installed, remove first. The plug adapter could not be installed when the
service valve still connected to the access fitting.

1. Attach the pipe plug adapter to the square head of the pipe plug and tighten
the L-key head set screw.

2. Install the service valve onto the access fitting body. Turn the hammer nut
(20) service valve clockwise until it securely seated. Tap the hammer nut (20)
tight using brass hammer.

3. Install the retriever onto service valve, turn and tap hammer nut (2) tight by
using brass hammer. With one hand on the retrieval tool handwheel (11), use
the other to remove the handwheel lock-pin (10) and place it in it’s keeper
(storage) hole.

IOM RETRIEVER TKS RP 19

 KOROSI SPECINDO

4. Slowly rotate handwheel (11) clockwise to move the spring (B5) loaded
socket adapter (1B) to the plug adapter. Slowly turn the T-handle (28) 3-5
turns to engage the landing screw (B1) in the plug adapter. Check for
engagement by attempting to rotate the handwheel (11) counterclockwise.
The handwheel should not rotate. If it does rotate, repeat the start of this
step. With slight clockwise pressure on the handwheel turn the T-handle (28)
in the clockwise direction until the spring loaded socket seats on the plug
adapter. With continue pressure on the handwheel, turn the T-handle (28) in
the counterclockwise direction 2-5 turns.

Note: You should notice system pressure equalizing past the plug
assembly into the retrieval tool body after approximately two (2)
turns of the T-bar handle (28).

CAUTION: Do not rotate the T-bar handle (28) more than five (5) times
without equalization occurring. If pressure does not equalize, you
must have the tool back pressured to equal or to slightly exceed
system pressure to successfully accomplish plug retrieval.
Equalization may be verified by checking the pressure gage on
the retrieval tool. As you rotate the T-bar (28), you will notice the
handwheel is rotating in the run-out direction.

5. Repeat 3.2. Removing Procedure steps 8-14.

IV. Maintenance
4.1 Retriever TKS RP
The maintenance interval required by either the TKS RP retriever will vary depending
upon the service to which it is subjected. Certain fluids will wash out all lubricant from
the retriever after one retrieval; others will deposit debris in the retriever making
operation difficult.

If the retriever has been in use and it is anticipated not being used for a period longer
than one day, it should be completely disassembled, cleaned and lubricated. Also, if
in a days operation (because of adverse retrieval environment conditions) the
retriever becomes difficult to operate, feels gritty and does not rotate easily
(handwheel), it should first be cleaned 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 point A and B of this
Section.

Lubricant choices are many. For a particular service, some experimentation may be
necessary. Recommended lubricants are:
1. Motor Oil – (SAE 30 weight or equivalent).

2. Lubricate (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 0o
to +350oF (-18 o to +177oC).

3. Synthetic lubricant – molybdenum disulfide grease containing rust and oxidation

inhibitors. It is recommended for use in extreme pressures and temperatures (-
40o to +600oF, -40o to +316oC).

IOM RETRIEVER TKS RP 20

 KOROSI SPECINDO

4.1.1 Sour Gas Service

On both the RP6000 retrievers, applicable materials comply with the
requirements of NACE standard MR0175, “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 retriever is used in
sour environments, it must be thoroughly cleaned after use to help prevent
corrosion and/or damage to internal materials.
The maintenance interval required for the retriever is dependent on the
frequency of use and the operating media. Recommended interval for the
following media is:

Type Of Media Weeks

1 Crude Oil 1
2 Refined Hydrocarbon 2
3 Natural Gas 2
4 Produced Water 1
5 Sea Water 2
6 Steam 2

Except with the presence of:

1. H2S, CO2, or O2
2. Chlorides or Sulphate
3. Acids, Alkalis, Amines or Glycols
4. Sand, grit, Clay or Maine Shells
5. Metal chips due to hot tapping
It should be cleaned on every day that it is used.

A. Overhaul Procedure
1. Back Tube Removal, remove back tube (29) from tool by first removing set
screw (7) and rotating back tube off counterclockwise with spanner wrench
provided in tool kit.
2. Gear Rack Removal, remove spline rack (32) by removing end stop flathead
screw (33) and end stop (34) from rack. The spline rack can now be pulled
out from the front of the tool.
3. Drive Ring Removal, remove handles (28) from drive ring (27) by rotating
out counterclockwise. Remove both set screws (7) from the drive ring and
slide the drive ring off the dive tube (20) taking care not to lose the two keys
(26).
4. Bearing Cap Removal, remove bearing cap (22) from the gear box (8) by
first removing each set screw (7) and rotting the bearing cap out
counterclockwise with the spanner wrench provided.
5. Thrust Bearing Removal, the thrust bearing (21) can now be removed from
the bearing cap by gently tapping the threaded side of the bearing cap on a
block of wood.
6. Drive Tube Removal, the drive tube (20) can now be pulled straight out of
the gear box.

IOM RETRIEVER TKS RP 21

 KOROSI SPECINDO

7. Front Tube Removal, remove the front tube (3) from the gear box by first
removing set screw (7) and then backing the gear box out of the front tube by
rotating counterclockwise.
8. Union Nut Removal, first unscrew counterclockwise the pressure gauge (6)
and bleed valve (6A) from front tube by using a wrench on the flats provided.
Then remove the spiral retainer ring (4) by prying the lead end out of the
groove and sliding the spiral retainer ring off the end of the front tube. The
hammer union (2) can now be slid off the front tube.
9. Gear Shaft Removal, place the gear box (8) in a soft jawed vise and by
holding the handwheel (11) remove nut (9) from the gear shaft using the 1-
1/16” socket wrench provided. The handwheel can now be pulled free of the
gear shaft. Now place shaft retainer wrench over the gear shaft and back the
shaft retainer (12) out counterclockwise. The gear shaft can now be pulled
free of the gear box.
10. End Cap Removal, the end cap (31) can be removed, if necessary, from
back tube (29) by first removing the set screw (7) and rotating the end cap
counterclockwise with the spanner wrench.
11. Adapter Assembly Removal, remove the spirol pin (A6 or B6) from the
adapter assembly (1A or 1B) by using a punch and hammer. The adapter can
now be pulled free of the spline rack (32).
12. Seal Inspection, removes all seals from tool, degrease, and check for wear
and nicks.

TROUBLE SHOOTING GUIDE

Problem Possible Cause Possible Solution

Connection binding 1. Set screw not clear of 1. Remove set screw from
during removal threads connection.

2. Possible galling 2. Tap Connection with hammer

while backing off thread
Threads binding 1. Possible galling 1. Do not proceed, back thread off
during make-up while tapping with a hammer,
deburr, polish and grease
threads prior to making up
connection.
Gear shaft binding 1. Gear shaft retainer 1. Use thinner thrust washers, or
after assembly tightening down on thrust remove one thrust washer on
washer gear box side.
Tool leaking at 1. Wrong O-ring 1. Consult parts list for proper seal
connections under size.
test pressure
2. Replace damaged seals and
redress seal surfaces.
Pipe threads on 1. Improper thread make-up 1. Use Teflon tape or dope on
gauge or bleed valve connections.
leaking
Grease fitting 1. Ball not seated 1. Grease with grease gun and
leaking through full pressurize the tool. Note: if fitting
port still leaks, replace.

IOM RETRIEVER TKS RP 22

 KOROSI SPECINDO

B. Assembly Procedure

1. Gear Box, place thrust washers (15) on gear shaft (14) using two washers on
each side of the gear. Slide O-rings (16) on gear shaft, coat shaft with
bearing grease rated at desired operating temperature and slide gear into
gear box (8). Place O-ring (13) on shaft retainer (12) and screw clockwise
into the gear box.
2. Front Tube, slide the hammer union (2) onto front tube (3). Slide spiral
retainer ring (4) in place. Place O-ring (17) on the gear box. Apply grease to
O-ring and threads and screw front tube onto gear box. Tighten with strap
wrench and install set screw (7) in place.
3. Bearing Cap, install the Omni seal (18) on the drive tube (20) with the spring
side of the seal facing outward.
CAUTION: Take care not to scratch or deform the seal. If the seal should
become deformed, heat it and the drive tube in an oven at 400˚F
for fifteen minutes and allow cooling prior to assembly. Grease
seal (18) and flange bearing (19), then slide the drive tube into
the gear box. Grease thrust bearing (21) and slide over drive
tube. Note that the small “ID” of thrust bearing is toward drive
tube flange. Place O-rings (24 and 35) into the bearing cap (22).
Grease and screw the bearing cap onto the gear box, and
secure with two set screws (7).

4. Drive Ring, put two keys (26) in the keyways on the dive tube and slide the
drive ring (27) in place. Secure with two set screws (7). Install handles (28)
on the dive ring by threading in clockwise.
5. Spline Rack, install the proper adapter assembly body (TKS 201 or TKS
209) onto the spline rack (32) by sliding the adapter assembly (1B) over
spline rack and retaining with spirol pin (B6).
6. Back Tube; install the O-ring (38) in the end cap (31). Grease and screw the
end cap clockwise onto the back tube (29) and secure with set screw (7).
Slide the assembled back tube over the spline rack, coat with grease and
screw clockwise onto the drive tube. Secure with set screw (7).

4.2 Service Valve

The maintenance interval required for the service valve will be determined by the
media acting upon the valve and frequency of use. Sand, grit or metal chips may
damage seats causing leaks which will require seat replacement. The recommended
interval for the following media is:

Type Of Media Weeks

1 Crude Oil 1
2 Refined Hydrocarbon 2
3 Natural Gas 2
4 Produced Water* 1
5 Sea Water* 2
6 Steam* 2

IOM RETRIEVER TKS RP 23

 KOROSI SPECINDO

* The valve should be rinsed with diesel fuel after each day’s service in these
environments.
Except with the presence of:
1. H2S, CO2, or O2
2. Chlorides or Sulphate
3. Acids, Alkalis, Amines or Glycols
4. Sand, grit, Clay or Maine Shells
5. Metal chips due to hot tapping
It should be cleaned on every day that it is used.

Occasional lubrication will be necessary to reduce opening torque. The use of a

synthetic lubricant is recommended.

4.2.1 Service Valve Disassembly

The TKS service valve has a valve ball that is removable only from the
service valve hammers nut end (access fitting body connection).
1. Loosen and remove cap screw (4) on handle (5) service valve. Remove
handle (5) from stem (3), remove plate position stop (25).

2. Place the service valve upside down (it will be better if placed in a vice to
secure it when removing interior parts from service valve. If this is done,
wooden block should be used to protect the body from marks caused by
vice jaws).

3. Loosen and remove the four Allen cap screw 7/16” (23) by using a 5/16”
Allen wrench. Loosen and remove the two cap screw ½” (24) by using a
3/8” Allen wrench. Remove the bonnet (2) from service valve body (1).
Remove back up ring (8), seal stem (9), thrust ring (10) and o-ring (11)
from stem. Care must be taken in removing the seal stem (9) and o-ring
(11).

4. Loosen and remove the four Allen cap screw 5/8” (19) at the hammer nut
end (20) by using a ½” Allen wrench.

5. Remove hammer nut (20), retainer (16), carrier seat (13), valve ball (12)
(care must be taken in handling of ball) and carrier seat (13).

6. Remove the needle valves only if necessary for seal replacement. To

remove; turn the large bleed screw retaining locks nuts counter-clockwise
and completely disengage from the service valve body. To disassembly
the bleed screws from their retaining lock nuts, it is necessary to remove
the roll pins and the small anti vibration 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. Seat replacement cannot
be accomplished.

7. Loosen and remove pipe plug (21) from service valve body (1).

4.2.2 Service Valve Assembly

1. Clean all parts. A recommended cleaning solution for all metal parts is a
mixture of 5 gallons (20 liters) of diesel fuel, ½ pints (250 ml) of standard
motor oil and two tablespoons of methanol. A soft brush such as a test
tube cleaning brush may be used to remove any deposits.

IOM RETRIEVER TKS RP 24

 KOROSI SPECINDO

2. Lubricate inside service valve body (1), lubricate carrier seat (13) and
install ring seat seal (15) into carrier seat (13), install o-ring (14) into
carrier seat (13).
NOTE: That there are two seat seal rings and carriers; and, that they are
interchangeable. There is only one carrier seal and it is to be
installed on to the carrier going into the ACME threaded end of
the service valve). If the seat seals are not being replaced,
install the better of the two seat seals in the ACME threaded end
of the service valve. Grease the face of the seat seal.
3. Place valve body (1) upside down (in a vice if possible using a wooden
blocks) then replace carrier seat assembly (13) into service valve body (1)
with o-ring (14) contact inside service valve body (1).

4. Lubricate the valve ball (12) and install the better side in the ACME
threaded end of the valve body (1). Ensure that’s the groove side on
valve ball (12) facing the stem (3). Then repeat item steps 3, install carrier
seat assembly into service valve body (1) with ring seat seal (15) facing
the valve ball (12).

5. Lubricate the retainer (16) (both side) then assembly o-ring (17 & 18).
Install retainer assembly (16) into service valve body (1). Install hammer
nut assembly (20) into service valve body (1) screw with the four 5/8” (19)
Allen cap screw by using a ½” Allen wrench. DO NOT tighten them
securely at this stage.

6. Partially assembly the bonnet (2) by installing the back-up ring (8) and
stem seal (9) in the bonnet (2). Install the thrust washer and stem in the
bonnet. Position the bonnet-to-valve body ‘O’ ring in the valve body (1)
stem recess.

7. Install the thrust ring (10) and stem (3) in the bonnet (2). Position the
bonnet-to-valve body is o- ring in the valve body (1) stem recess.
Carefully position the bonnet onto the valve body, ensuring that the thrust
washer is eased into position concentric with the ‘O’ ring. Stager torque
the four 7/16” Allen head cap screws to 30 ft.lbs. And the two ½” Allen
head cap screws retaining the bonnet to the valve body to 50 ft.lbs. Use a
5/16” and 3/8” Allen wrench, respectively.

8. Carefully position the bonnet (2) onto the valve body (1), ensuring that the
thrust ring (10) is eased into position concentric with the o- ring (11) and
ensure that the stem (3) inserted into valve ball groove. Stager torque the
four 7/16” Allen head cap screws (23) to 30 ft.lbs. And the two ½” Allen
head cap screws (24) retaining the bonnet (2) to the valve body (1) to 50
ft.lbs. Use a 5/16” and 3/8” Allen wrench, respectively.

9. Install the plate position stop (25) over the top of the stem (3) and position
the valve ball handle (5) onto the square head of the stem (3). Ensure
that handle (5) positioning points away from the hammer nut end (20)
when the valve ball (12) is in the open position. Tighten the cap screw (4).

10. Stager torque the four 5/8 “ Allen head cap screws (19) that were initially
installed as indicated in item steps 5 to 130ft. lbs, to retain the hammer
nut assembly (20) and retainer (16).

IOM RETRIEVER TKS RP 25

 No. Dok : KRT-03-01

19

31
7
38
8
16
36 15
14
29 15
17
16
13
33
11
34 10

7 12 9
32
40

26

27 25

28
7

22
36 3

7
1B
24
B6

23 7
B2 6
B3 6C 6B
21 B4
B3 4
6A
35
B5
7
2
30 6E
B1
20
6D

18
39

37

11 HANDWHEEL BODY ALUMUNIUM 1 EA TKS230

10 LOCK PIN 304 SS 1 EA TKS229 40 ALUMUNIUM
HANDWHEEL HANDLE 1 EA TKS259
9 HAND WHEEL NUT CS 1 EA TKS228
39 ADAPTER THREAD 316 SS 1 EA TKS258
8 GEAR BOX CAST 316L SS 1 EA TKS227
38 O'RING VITON 1 EA TKS257
7 SET SCREW SS 5 EA TKS226
37 O'RING VITON 1 EA TKS256
6E PIPE PLUG NPT 316 SS 1 EA TKS225 36 CS
1/4" NPT FITTING GREASE 2 EA TKS255
6D MALE HOUSE CONNECTOR 316 SS 1 EA TKS224 VITON EA
35 O'RING 1 TKS254
6C HEX NIPPLE 316 SS 1 EA TKS223 34 316 SS
END STOP 1 EA TKS253
6B PRESSURE GAUGE 316 SS 1 EA TKS222
33 FLAT HEAD SCREW 304 SS 1 EA TKS252
6A BLEED VALVE 316 SS 1 EA TKS221 32 17-4PH
SPLINE RACK 1 EA TKS251
6 PRESSURE GAUGE ASSY 316 SS 1 EA TKS220
31 END CAP 316 SS 1 EA TKS250
5 1/4" NPT BLEED VALVE 316 SS 2 EA TKS219 30 O'RING VITON 1 EA TKS249
4 SPIROL RING FOR HAMMER UNION 316 SS 1 EA TKS218 316 SS
29 BACK TUBE 1 EA TKS248
3 FRONT TUBE 316 SS 1 EA TKS217
28 HANDLE 316 SS 2 EA TKS247
2 HAMMER UNION CS 1 EA TKS216
27 DRIVE RING 316 SS 1 EA TKS246
B6 SPIROL PIN 304 SS 2 EA TKS215 26 KEY AISI 1018 2 EA TKS245
B5 SPRING SS 1 EA TKS214
25 SET SCREW SS 2 EA TKS244
B4 ADAPTER GUIDE 316 SS 1 EA TKS213 24 O'RING VITON 1 EA TKS243
B3 SPIROL RING FOR ADAPTER BODY 316 SS 2 EA TKS212
23 SLEEVE BEARING P/M BRONZE 1 EA TKS242
B2 ADAPTER BODY 316 SS 1 EA TKS211 22 BEARING CAP 316 SS 1 EA TKS241
B1 LANDING SCREW 316 SS 1 EA TKS210
21 THRUST BEARING AISI 52100 1 EA TKS240
1B HP ADAPTER ASSY AS LISTED 1 EA TKS209 20 DRIVE TUBE 316 SS 1 EA TKS239
A7 ADAPTER BODY 316 SS 1 EA TKS208
19 FLANGE BEARING P/M BRONZE 1 EA TKS238
A6 SPIROL PIN 304 SS 1 EA TKS207 18 OMNI SEAL FLUOROCARBON 1 EA TKS237
A5 SET SCREW SS 1 EA TKS206
17 O'RING VITON 1 EA TKS236
A4 MH SPANNER 316 SS 1 EA TKS205 16 O'RING VITON 4 EA TKS235
A3 ADAPTER GUIDE 316 SS 1 EA TKS204
15 THRUST WASHER 316 SS 4 EA TKS234
A2 SPIROL RING 316 SS 2 EA TKS203
14 GEAR SHAFT 17-4PH 1 EA TKS233
A1 COLLET LATCH 17-4PH 1 EA TKS202 13 O'RING VITON 1 EA TKS232
1A MH ADAPTER ASSY AS LISTED 1 EA TKS201
12 SHAFT RETAINER NIT 60 1 EA TKS231
ITEM DESCRIPTION MATERIAL QTY UNIT PART NUMBER ITEM DESCRIPTION MATERIAL QTY UNIT PART NUMBER

KOROSI SPECINDO
JAKARTA - INDONESIA

RETRIEVER ASSY
 No. Dok : KRT-03-01

 


 

10 LOCK PIN * 304 SS 1 EA TKS230 40 HANDWHEEL HANDLE * ALUMINUM 1 EA TKS260

9 HAND WHEEL NUT 3/4" - 10UNC * 304 SS 1 EA TKS229 39 ADAPTER THREAD 316 SS 1 EA TKS259
8 GEAR BOX 316L SS 1 EA TKS228 38 O'RING (124) VITON 1 EA TKS258
7 SET SCREW 3/8" - 16UNC 304 SS 10 EA TKS227 37 O'RING (232) VITON 1 EA TKS257
6E PIPE PLUG NPT 316 SS 1 EA TKS226 36 1/8" NPT FITTING GREASE SS 2 EA TKS256
6D MALE HOUSE CONNECTOR 316 SS 1 EA TKS225 35 O'RING (231) * VITON 1 EA TKS255
6C HEX NIPPLE 316 SS 1 EA TKS224 34 END STOP 316 SS 1 EA TKS254
6B PRESSURE GAUGE 316 SS 1 EA TKS223 33 FLAT HEAD SCREW 304 SS 1 EA TKS253
6A BLEED VALVE 316 SS 1 EA TKS222 32 SPLINE RACK 17-4PH 1 EA TKS252
6 BLEED VALVE ASSY 316 SS 1 EA TKS221 31 END CAP 316 SS 1 EA TKS251
5 1/4" NPT BLEED VALVE 316 SS 1 EA TKS220 30 O'RING (123) VITON 1 EA TKS250
4 SPIROL RING FOR HAMMER UNION CS 1 EA TKS219 29 BACK TUBE 316 SS 1 EA TKS249
3 FRONT TUBE 316 SS 1 EA TKS218 28 HANDLE 316 SS 2 EA TKS248
2 HAMMER UNION CS 1 EA TKS217 27 DRIVE RING 316 SS 1 EA TKS247
B7 ORING (4 x 18) VITON 1 EA TKS216 26 KEY * AISI 1018 2 EA TKS246
B6 SPIROL PIN 304 SS 2 EA TKS215 25 ORING (229) VITON 2 EA TKS245
B5 SPRING SS 1 EA TKS214 24 O'RING (223) VITON 1 EA TKS244
B4 ADAPTER GUIDE 316 SS 1 EA TKS213 23 SLEEVE BEARING * P/M BRONZE 1 EA TKS243
B3 SPIROL RING FOR ADAPTER BODY 316 SS 2 EA TKS212 22 BEARING CAP * 316 SS 1 EA TKS242
B2 ADAPTER BODY 316 SS 1 EA TKS211 21 THRUST BEARING AISI 52100 1 EA TKS241
B1 LANDING SCREW 316 SS 1 EA TKS210 20 DRIVE TUBE 316 SS 1 EA TKS240
1B HP ADAPTER ASSY * AS LISTED 1 EA TKS209 19 FLANGE BEARING * P/M BRONZE 1 EA TKS239
A7 ADAPTER BODY * 316 SS 1 EA TKS208 18 OMNI SEAL FLUOROCARBON 1 EA TKS238
A6 SPIROL PIN * 304 SS 1 EA TKS207 17 O'RING (63 x 3) VITON 2 EA TKS237
A5 SET SCREW * SS 1 EA TKS206 16 O'RING (206) * VITON 4 EA TKS236
A4 MH SPANNER * 316 SS 1 EA TKS205 15 THRUST WASHER * 316 SS 4 EA TKS235
A3 ADAPTER GUIDE * 316 SS 1 EA TKS204 14 GEAR SHAFT 17-4PH 1 EA TKS234
A2 SPIROL RING * 316 SS 2 EA TKS203 13 O'RING (213) * VITON 1 EA TKS233
A1 COLLET LATCH * 17-4PH 1 EA TKS202 12 SHAFT RETAINER * NIT 60 1 EA TKS232
1A MH ADAPTER ASSY * AS LISTED 1 EA TKS201 11 HANDWHEEL BODY ALUMINUM 1 EA TKS231
ITEM DESCRIPTION MATERIAL QTY UNIT PART NUMBER ITEM DESCRIPTION MATERIAL QTY UNIT PART NUMBER *

KOROSI SPECINDO
JAKARTA - INDONESIA

RETRIEVER RP6000 ASSY

 No. Dok : KRT-03-01

6
5

4
25
24
(2EA)

23
(4EA)

22
2
8
9
10
11

IOM RETRIEVER TKS RP 1

1

14
13

15

12

13
20
17
16
19
(4EA)
18

KOROSI SPECINDO
JAKARTA - INDONESIA

SERVICE VALVE PART

KOROSI SPECINDO
 KOROSI SPECINDO

No. Dok : KRT-03-01

21 22 23 24 23

27 25

7 6

26

8
3
9
10
11
2 1

12

13 14 15 16 17 18 19

20
SEC. A
KOROSI SPECINDO
JAKARTA - INDONESIA

SERVICE VALVE ASSY

3600 PSI

IOM RETRIEVER TKS RP 2