KS MNL ENG 01 02 (Corr - Monitoring)

PT.
KOROSI SPECINDO
Corrosion Monitoring Systems
Engineering Doc. No.:
KS-MNL-ENG-01-02-Rev0
INSTALLATION, OPERATION & MAINTENANCE

INSTRUCTIONS
2” SYSTEM CORROSION MONITORING
Rev Date Prepared Checked Approved Description

0 Sept/27/2004 Sam Hary P GM Issued for approval
IOM 2‖ System Corrosion Monitoring 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 COMPLETLY BEFORE COMMENCING THE

WORK
This procedure is an installation operating manual for proper operate
this product only, The operator must be follow the national safety
CAUTION procedure as a common and or other local or company regulation as
well. Something in doubt, ask Korosi Specindo PT.
All instruction in this procedure does not cover any installation
procedure
1. Requirements for protecting the fitting and ensuring usable installation

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 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) Where 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.
Note: * Only retriever up to 30‖ stroke (full extend position).

** Only retriever up to 54‖ stroke (full extend position).
KS-MNL-ENG-01-02-Rev0 Page 1 of 51
1/16‘‘ 1/16‘‘
FLARWELD BUTTWELD
A/F A/F
1/16‘‘ 1/16‘‘
NPT A/F SOCKETWELD

A/F
Fig.1. Access Fitting

b) Installation Flanges
When installing flanges, suggestion sequence for tightening flange bolts as shown in
fig. 2. To provide even sealing pressure on the flange gasket,
1 the bolt should be traverse hand tightened according to the
5 8 sequence until the flange faces are in contact with the gasket.
Then firmly tighten the bolts in the same sequence.
3 4
3 Note: ―Hot Flow‖ of gasket material may occur operating
conditions. Resulting in loss of bolts pressure. Bolts should be
7 6 retightened after operating temperature has been reached.
7 2
2
Fig.2. Flange Bolts
B. Welding of Korosi Specindo Access Fitting

a. Safety Considerations
To maintain control of condition under which welding is to be done, the responsible
supervisor in charge must be:
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,
nor on equipment which is operating at less than atmospheric pressure; that is, in
a vacuum.
2. Determine if air is present, especially in combination with 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 is 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 are 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

water 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. Because they only require only one
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, ASME
B31.3 Chemical Plant & Refinery Piping.
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:
a. Carbon Steel
1) Tack Weld. Preheat the fitting to 315 oC (600 oF). 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.
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 internal threads (UNF) by using a thread brush (refer to section V. IV. E
Special Procedures for Access Fitting)
2. Cleaning and repair seat seal plug on the access fitting by using a Seat Reamer
(refer to section V. IV. E Special Procedures for Access Fitting)
3. Cleaning and repair internal threads (UNF) by using a Thread Tap Assembly
(refer to section V. IV. E Special Procedures for Access Fitting).
4. Grease external thread (ACME)
5. Check access fitting face up end (O-ring seat Protective cover) for scratch, use a
smooth sand paper and bastard to repair.
SECTION II
HOT TAPPING
I. Introduction
This procedure describes Hot Tapping work to ensure the safety of personnel,
plant and equipment during Hot Tapping operations. Hot Tapping is defined as
using an under pressure drilling machine to cut a hole in an operating pipeline
allowing for a new take off from the original pipe. This process should be done
without any product leakage or loss. Hot tapping can be proceeding after NDT and
or Hydrostatic test has been conduct.
N.B.: Hot Tapping should be avoided, if possible, unless it is proved not to be

practical to isolate the plant & perform the work under isolated conditions.
II. Safety
a. Personnel
1. Safe operation requires minimum 2-trained operator.
2. Test and check should be done to all equipment before attempting to use in field.
3. Do not use this hot tapping equipment unless you have been trained in its safe.
4. Make sure you have complied with all plant safety requirements and
environmental regulations.
5. Identify the type media its pressure and temperature. Review material safety data
information on the media prior to operation.
6. 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.
7. 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
8. Ensure you have scaffolding if the Access fitting that to be hot tapping is mounted above
the operator.
b. General
―Hot Tapping‖ is used to cut a hole in an operating line under pressure. This
method is only used when no other suitable means of accomplishing the objective
is available. All personnel concerned should be aware of the precautions to be
taken, which are:
 All Hot Tapping work must be conducted under conditions of the Work
Permit System and the condition of such permits must be strictly adhered
to.
 A Production Operation must be present during Hot Tapping work.
 A Safety Officer must continuously monitor the task.

 Communications must be established with the Site Control Room to ensure
process conditions are suitable prior to and during Hot Tap operations.
 All welding heat treatment, NDT and hot tapping process are to be
approved by Head of Inspection.
 Fire Extinguisher is available for use near the working area.
 Isolate the working area.
Some equipment is unsuitable for Hot Tapping because of metallurgy or thickness

of metal. Hot taping fitting and weld rod metallurgy must be compatible with
equipment, piping, vessels, etc. to be tapped.
Hot Tapping must also be avoided upstream of rotating equipment unless such
equipment is protected from the cutting by means of filters or traps.
No attempt must be made to Hot Tap atmospheric pressure petroleum storage

tanks near to or above liquid level because of the danger of an explosive
atmosphere inside the tank. A thorough and complete inspection of each
connection location must be made to verify that the metal thickness is adequate for
the pressure and temperature involved and that the area is free from internal
defects, particularly laminations.
A detailed written procedure approved by the Head of Inspection must be prepared

for each specific Hot Tapping operation, identifying as a minimum:
 Pipe/vessel material specification and wall thickness.
 Contents of the system.
 Required process conditions.
 Qualified Welding equipment/consumable.
 Emergency procedures.
 All equipment necessary to complete the work.
 Site NDT Procedure & acceptance standards (inc. pressure tests).
III. Operation
3.1 Preparation
 Re-checked all equipment condition before proceed the work.
 Determine the condition of area.
 Clean the area that is going to be weld or hot tapping.
 Determine the wall thickness of the pipeline/vessel before conducting any
welding or hot tapping (Do Not weld if less than 3 mm according to
manufacturer recommendation).
 Ensure that after welding process there‘s no intrusive weld inside access
fitting, repair if any.
 Pour cutting oil into access fitting body approx. 1‖ depth.
3.2 Process
The HOT TAP MACHINE is a manual feed machine. Clockwise rotation of the
feed tube extends the boring bar and counterclockwise rotation retracts the
boring bar. With the socket head set-screw tightened, turning the hex drive
clockwise both turns and extends the boring bar. One revolution of the hex
drive will extend the boring bar 1/8‖.
NOTE: The socket head set screw is to be tightened only when operating
high pressure. Do not tap or drill with the set-screw tightened.
CAUTION:
 When tapping, be sure you do not OVERFEED. 0ver feeding, and
underfeeding also, will damage the hollow drill or cutter.
 Ensure that cutter do not interfere with ball of the service valve.
 Measurement drilling depth must be made prior to hot tapping operation.
1. Connect the service valve to the fitting. Lift the service valve and place it on
the access fitting body. Turn the hammer nut clockwise until the service
valve is securely seated. Tap the hammer nut tight using a brass hammer.
The valve should be in ―OPEN‖ position.
2. Attach machine to service valve. Operate service valve to make sure it
opens and closes without interference from tip of cutter. Be sure valve is in
full open position before continuing to next step.
3. Begin Tap
Drive drill through service valve and access fitting until drill contact with
pipe surface. Determine measurement of drilling depth by using a caliper
and paint marker. Measurement drilling depth is defined by actual wall
thickness and added ½‖ than actual wall thickness (mark across on
measurement body tube). Connect air motor (if possible) or manual driven
by attach ratchet handle to 3/4" hex drive. While a ratchet handle is
furnished, best results will be obtained if handle is rotated 360° while
cutting. Turn clockwise only. The rate of advance for the hollow drill is
determined by the advance of the feed tube. Do not overfeed to prevent
damage to the cutter. Eight revolutions of the feed tube will lower the cutter
one inch. Rotate slowly during last inch of travel to prevent damage to the
tip of the cutter.
As pilot drill penetrates pipe wall, line fluid will completely fill valve, fitting
and adapter. Connect a diverter hose to release pressure and metal chips.
After all air is purged, CLOSE Bleeder Valve. Vent pressure bleed valve
away from work area and personnel in a spill container. Stand clear of vent
when bleeder valve is opened. Otherwise, personal injury may result from
blowing material. Each time cutter drilling approx. 5 mm release pressure to
prevent too much metal chips during hot tapping on hot tap machine.
4. Complete Tap
When second mark or lower mark (total travel distance) is reached on body
tube, tap should be complete. At this point, the feed tube should turn with
little effort. The "feel" and rate of feed confirm the tap to be complete.
5. Retract Cutter
By rotating feed tube counterclockwise, retract cutter until feed tube is at
the zero mark on body tube or until it comes to firm stop. If line is under
high pressure, it may be necessary to tighten the set-screw and retract the
cutter by using the ratchet handle.
6. Recovery Sequence
 Close the service valve
 Bleed off pressure trapped in hot tapping by connect diverter hose

and opening bleeder valve. Stand clear of diverter hose and hot tap
machine.
 Remove diverter hose from hot tap machine.
 Remove hot tap machine from service valve. And remove coupon
from cutter.
 While service valve still in closed position, connect surge tube for
complete metal chips release (refer to section V. IV. E Special
Procedures for Access Fitting-Surge Tube for detail procedures)
CAUTION: High temperature tap — after each high temperature tap

above 350° F, or taps in corrosive fluids, replacement of
packing is recommended. Equipment damage might
otherwise result.
IV. Maintenance
The T KS6000 T-HT Hot Tap Machine has been designed for rugged service and
requires a minimum amount of maintenance. A reasonable amount of care will
keep the machine in top operating condition for a long period of time. Following are
recommendations for proper care and handling.
a. The exposed end of the boring bar should be protected when machine is not
in use.
b. Use an open end or adjustable type flat wrench on the two flat surfaces
provided when attaching the machine to a service valve or adapter hammer
nut.
c. After each use, clean dirt and foreign material from exterior of machine.
d. Care should be taken not to damage hex drive at top of machine.
e. Lubricate ratchet handle regularly with oil.
f. After each tap, inspect cutter holder for any damage.
g. Disassemble and lubricate each part every six (6) months or Twenty (20)
taps, whichever comes first, following the procedures.
h. High temperature tap — after each high temperature tap above 350° F, or
taps in corrosive fluids, replacement of packing is recommended. Procedures
for packing replacement follow.
i. The cutter holder and cutter are parts to be protected from corrosion by an oil
coating. These parts should be inspected regularly and recoated with oil
before storing.
4.1 Machine Disassembly

a. Hold body tube and rotate feed tube clockwise until boring bar is fully extended
from body tube. The feed tube should be at the 18" mark on the body tube.
b. Loosen socket head set screw on the bearing and cap retainer.
c. Using packing wrench provided, remove retainer nut next to bearing at top of
machine by turning counterclockwise.
d. Remove snap ring and three piece thrust bearing at top of machine.
e. Using packing wrench provided, remove packing retainer nut from body tube by
turning clockwise threads are left handed. Remove packing.
f. Remove boring bar through bottom of machine.

g. Hold body tube and rotate feed tube counterclockwise until threads are
disengaged. With draw body tube from feed tube.
4.2 Machine Reassembly

Reassembly procedures are basically the reverse of steps ―c‖ through ―f‖,
Machine Disassembly. However, the following additional information is
provided and refers to various steps in the disassembly procedures.
1. Grease all parts prior to assembly.
2. Replace packing (step e & f). Replace packing with high temperature packing.
Enough sections should be used to make a stack 1" high. The grooves should
be greased and inserted one section at a time with the lip toward the bottom.
3. Packing retainer nut (step c & d). Inspect packing retainer nut. A nylon insert
on the side serves as a lock washer. Inspect this insert for condition.
4. Packing retainer nut (step c & d). Remember that the packing retainer nut has
left handed threads. Turn counterclockwise to install. Tighten firmly, making
sure that boring bar will rotate without excessive torque.
5. Install thrust bearing (step d). When replacing three pieces thrust bearing at
top of machine, grease each bearing individually. Inspect snap ring.
SECTION III
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 of Number of Dimension of Type of Flow

Pressure Density Viscosity
Platform Pipeline Pipeline Fluid Rate
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.
Coupon Observation Appearance Date

Removal Date of Report of
Serial Mechanical of scale & of Send to
Date Photograph Analysis
Number Damage corrosion product Laboratory
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 wrapped properly in VCI Paper can remain protected
two years, for best result after two years storage coupon should be blasting.
SECTION IV
INSTRUMENTS AND CORROSION PROBE
I. Introduction
This practice covers procedures for preparation, process of installation, Setting
parameter and Trouble shooting the DCI (Data Collection Instrument). Download DCI
is using KSHHU. Saving into file and making standard report or finding on the field.
II. Equipment
1. Fix Data Logger (DCI – Dx – ER/LPR – 01/04)
2. Transmitter (DCI – Tx – ER/LPR)
3. Portable Data Logger (KSHHU – ER/LPR)
4. Cable Communication and Connector
5. Electronics Tools set
III. Safety
1. Test and check should be done to all equipment before attempting to use in
field.
2. Provide a secure operation which requires minimum 2-trained operators.
3. Verify with Instrument Supervisor to determine where will be the most
appropriate and the closest location toward the Instrument Panel Complex
located.
4. Ask for an approved welder if you plan to mount DCI using Environment
Protection Box (EPB) structure to the existing or nearest location to Instrument
Panel Complex in Offshore.
5. Make sure that the users have complied all plant safety requirements and
environmental regulation procedures.
6. Also ensure that the user already has all of required safety equipments i.e.
protection outfit, safety helmet, safety glasses, safety gloves, ear plug, safety
shoes and breathing apparatus when toxic atmosphere exists.
IV. Operation
4.1 Preparation
1. Safety Procedure always ask for a person who will be in charged,
specifically as an Instrument, or Electrical, or Corrosion Engineer who will
take care your duty in the field during Installation DCI and other
accessories.
2. If you plan to protect the wiring between the Corrosion Probe and the DCI
or any related Instrumentation using Conduit for the first time or during your
field survey, always prepare Sketch Drawing or Draft on the notebook of
every length, position, and angle of direction. Make sure that the conduit
accessories to be as efficient as possible, and be located at the closest to

existing cable tray on that level and location.
3. During wiring process, do not cut any cable in a hazardous area if you are
not sure enough that the correct lengths of all cable for Instrumentation are
screened (armored) in overall length. So, you should not extent or make
any connection without Junction Box, except in Non Hazardous area.
Any extension or connection between two cables will result in unwanted
noise affecting the sensitivity of the signal and resulting in erroneous data
or malfunctioning of the monitoring system.
4. Always Test all of your Equipment before you move them to be installed on
the field. Prepare any tools required such as, spare ER/LPR probe,
extension probe, Probe Cable, Dummy Probe, Battery Pack etc.
5. Prepare Documentation and all Manual Book required in the field for having
Installation, setting parameter and Troubleshooting.
6. Probe should be new

Open the protective plastic and take out probe carefully. Avoid
contamination of probe caused by contact with oil or chemicals. Then
connect to KSHHU for ascertain condition of probe.
Record the following information:
- Probe serial number.
- Type of probe.
- Installation date.
- Name of system.
4.2 Installation Process

1. Install extension adapter on hollow plug body before attach protective
cover.
2. Connected probe cable to extension adapter (six-pin connector).
4.3 Setup and Operation

Having installed the battery pack, the instrument is ready to be operated. This
instrument is completed without display and keypad, to configure the
parameter, to transfer data and to delete files.
4.3.1 Taking Measurement

It will automatically read the probe at customer-selected intervals and
store data results in the memory.
4.3.2 Deleting Files

To delete files, either must use a KSHHU for hazardous area or PC for
safe area.
a. Using KSHHU-ER
1. Connect the DCI (Dx type) nine pin serial cable to the KSHHU
nine pin serial cable for hazard area (make sure that the battery
has been installed at DCI).
2. Turn on KSHHU and check the battery.
3. Press enter on standby menu display and select DCI setup
command from data logger setup display.
4. Select clear memory command from DCI setup display to reach

clear memory confirmation display.
5. Wait approximately 2 seconds to have a complete clear memory
processing on DCI (Dx type).
b. Using PC
1. Connect the DCI (Dx type) nine pin serial cables to the PC nine
pin serial cables in safety area (Make sure that your PC has
already installed KS-Corrosion Monitoring Software).
2. Open KS-CMS software application.
4.3.3 Setting the parameter

To Setting Parameter, either must use a KSHHU for hazardous area or
PC for safe area.
a. To set up the parameter on the field, apply KSHHU-ER

procedures as follow:
1. Make sure that the battery has been connected to electronics
box.
2. Connect DCI (Dx type) to KSHHU.
3. Set up the clock on DCI (Dx type), to make it equal with the time
and date on KSHHU.
4. Set up DCI (Dx type) configuration from KSHHU, press ―enter‖
button on standby menu display, then select Data Logger Setup,
next select DCI Setup and finally select Setting Parameter.
5. When it is completed, disconnect DCI (Dx type) from the
KSHHU and data collection will commence immediately.
b. To set up the parameter in safe area, apply PC’s procedures as
follow:
1. Make sure that the battery has been connected to electronics
box.
2. Connect DCI (Dx type) to PC. (Make sure that your PC is
already installed with KS-Corrosion Monitoring Software (KS-
CMS))
3. Open KS-CMS Software Application, tap on Data Logger menu,
and select set configure sub menu.
4. When it is completed, disconnect DCI (Dx type) from a PC and
data collection will commence immediately. (See KSHHU
manual to be more)
4.3.4 To download data through KSHHU-ER

To transfer data in the field, apply KSHHU procedures as follow:
1. Plug RS-232 cable communication of KSHHU into each DCI (Dx
type) in the field
2. Turn on the KSHHU and check the battery.
3. Press ―enter‖ button on standby menu display and then select data
transfer from main menu display.
4. Select download from DCI (Dx type) command from data transfer
display.
5. Go to the confirmation display:
6. If the cable is not connected, return to data transfer display.
If the cable is connected, go to the next process (Wait
approximately 2 seconds to have a completed checking cable).
7. Unplug cable and data will be stored in the memory.
4.4 Korosi Specindo Corrosion Monitoring Software (KS-CMS)

Each KSHHU-ER includes the Korosi Specindo Corrosion Monitoring Software
(KS-CMS). This program is a collection of utilities designed to assist the
corrosion analyst in gathering and analyzing corrosion data. When data was
uploaded to the software, the data can be displayed in graph. The output of the
printer, either in list or graph form, is suitable for any kind of printer. After data
is uploaded to PC, users can delete all data stored in memory KSHHU.
4.4.1 PC Requirements
To run the Korosi Specindo Corrosion Monitoring Software (KS-CMS),
you need a PC that meets the following requirements:
 Pentium® class processor
 Windows® XP operating system
 64 MB of RAM
 20 MB of minimum available hard-disk space
 lution
 Mouse or pointing device recommended
 Available 9-pin or 25-pin serial port (for instrument download)
 CD-ROM drive for software installation (software available on 3.5"
diskettes by request)
4.4.2 Installing KS-CMS

To install Korosi Specindo Corrosion Monitoring Software (KS-CMS):
1. Remove any previous installations of the software.
2. Insert the setup disk. If the setup program starts automatically.
3. From the Start menu, select Run. The Run dialog box should
appear.
4. In the Open field, type "x:\setup" where .x. is the letter of the CD-
ROM drive containing the setup disk.
5. Click OK. The setup program should now start.
6. You will be prompted to close any open programs. After you have
done so, click OK to continue.
7. You may change the directory that will contain the software by
clicking the Change Directory button. To install the software in the
default directory, click the Install button.
8. After clicking the Install button, the software will be installed on your
PC. If any errors occur during software installation, you should
uninstall, and then reinstall the software.
9. When the software installation is complete you should remove the
setup disk, and then reboot your computer.
4.4.3 Uninstalling KS-CMS

To uninstall the Korosi Specindo Corrosion Monitoring Software (KS-
CMS):
1. Open the Windows® Control Panel.
2. Open Add/Remove Programs.
3. Select Korosi Specindo Corrosion Software from the list.
4. Click the Change/Remove button.
5. Follow the prompts.
V. Mounting
DCI (Dx type) is mounted in field and equipped with Environment Protection Box
(EPB) to protect from environment disturbances such as sunlight, rain, wind or sea
breeze. Environment Protection Box (EPB) made from glass is filled with polyester,
for the application in harsh climates, Standard Enclosure NEMA 4X and IP66.
Environment Protection Box (EPB) recommended connects to earth ground.

Locate it within 8 meter of the installed probe. The purpose of Environment
Protection Box (EPB) is to protect DCI-Dx-ER-01 when operator comes to
download data and setting parameter on a rainy day or against the bright sunlight
in the field.
VI. Maintenance
DCI (Dx type) is require maintenance because malfunctions as no measurement

precession. Procedure as follow:
1. Ensure that the probe is operational and is not completely corroded.

2. Examine all electrical connections for proper electrical connections, signs of
corrosion and to ensure that the connections are environmentally protected.
3. Contact Korosi Specindo for technical assistance if the Data Logger continues
to malfunction is obviously damaged.
SECTION V
RETRIEVAL PROCEDURES
I. Introduction
This practice covers procedures for preparation, process of installation – removal
and safety consideration during retrieval corrosion coupon and probe.
II. Equipments
1. Retriever tools assembly
2. Service valve assembly
3. Mechanical tools set
4. Diverter hose assembly
III. 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 installation and extension of the
retriever and service valve. The following recommendations should give
adequate clearance:
14-14‖ Stroke - 4.5 feet (1.5 meters)
18-18‖ Stroke - 6 feet (1.8 meters)
34-34‖ Stroke - 8.5 feet (2.6 meters)
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.
IV. Operation
4.1 Preparation
Note: - Ensure by-pass service valve in ―OPEN‖ position.
c. Ensure bleed valve retriever and service valve in ―CLOSE‖
position.
a. Check condition of service valve.
Inspect the O-ring (18) at the hammer nut end for nicks, cuts and
abrading
b. Check condition of retriever.
Extend and collapse the retriever to ensure it‘s lubricated and operating
properly, check the condition of O-ring (25) at thread adapter.
c. Adjust the socket adapter assembly, for solid or hollow plug
assemblies the socket adapter should be set in the third and fifth holes
from the hex end.
d. Check pressure in pressure gauge in protective cover.
Note: If there‘s any indication pressure, release by opening bleed valve in protective
cover.
4.2 Removing Process

1. Remove the access fitting cover (protective cover) by using a spanner
wrench (―C‖ pin wrench).
2. Remove the pipe plug ½” NPT. Use a crescent wrench to remove pipe
plug slightly counter clockwise.
Warning : If for any reason there’s pressure behind the plug, after
one or 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 ―OPEN‖ position.
4. Connect the retriever to the service valve. If the access fitting to be

serviced is mounted on the top – of – line (12 O‘clock), install the locking
clamp on the inner barrel (22) to prevent the retriever outer barrel from
collapsing of its own weight.
Lift the retriever and place it on the service valve, turn the hammer nut (7)
clockwise until the retriever is seated on the service valve. Tap the
hammer nut (7) tight by using a brass hammer.
5. Back pressure the retriever if the tool cannot be balanced through

the service valve. Back pressuring is the pressuring of the retriever from
an external source through the retriever bleed valve before plug removal.
This is accomplished with the use of the backpressure service tool.
a) Connect the high-pressure hose of the back – pressure service tool to
the bleed valve (4) on the retriever. Tighten securely.
b) Open the bleed valve on the retriever (4). Uses the bleed valve (22)
vent on the service valve to bleed-off any air in the chamber. This
procedure may reverse. For bottom of the line application, back
pressure through the retriever bleed valve (4) with the service valve
bleed (22) open until fluid reaches that point. For top of line
applications, back pressure through the service valve bleed (22) with
the retriever bleed valve (4) open until fluid reaches that point.
c) Pressurize the assembly using the back - pressure service tool. Bleed
off air through the service valve bleed vent valve (22), as required.
Close the service valve bleed vent valve (22). (Refill the back -
pressure service tool with fluid as required).
d) Pressurize the assembly to 100 PSI above line pressure. Close the
retriever bleed valve (4). Bleed the pressure from the back - pressure
service tool hose through the backpressure service tool bleed valve.
6. Connect the socket adapter pilot. Remove the locking clamp if installed.
Collapse or move the outer barrel (20) toward the access fitting body until
the socket adapter pilot (41) contacts the plug assembly. Do not allow the
socket adapter hex to engage the plug assembly hex. (A turning, sliding
motion – as opposed to a straight sliding motion. Turn the outer barrel
(20) clockwise to engage the socket adapter pilot (41) thread to the
female threads of the plug assembly.
7. Connect the socket adapter hex (37). Collapse the retriever outer barrel
(20) toward the access fitting body while turning slightly clockwise until
the socket adapter hex (37) slides over the plug assembly hex.
8. Retriever “Pressuring – balancing”.

a) While still pushing in, turn the retriever outer barrel (20) slowly counter
clockwise to unseat and begin backing off the plug assembly.
b) Pressure balance will begin after 4 to 5 turns of the outer barrel (20).
Pressurization should be signified by pressure gauge reading, hearing
the fluid enter the retriever or feeling the increase in friction as the
seals experience pressure load. When the retriever begins to de-
pressurize, stop turning the outer barrel (20) and wait for at least 5
minutes for the retriever and line pressure to be balance.
9. Retrieving the plug assembly from the access fitting body. When the
retriever has ―pressure – balanced‖ with the line, continue pushing on and
rotating counter - clockwise the barrel (20) for approximately 14 - 16 turns
to fully disengage the plug from the access fitting body. Ensure that the
socket adapter hex (37) and plug assembly hex remain engaged during
this operation.
10. After the plug assembly is removed from the access fitting body, fully
extend the retriever outer barrel (20) with a twisting and sliding motion
until the plug assembly is withdrawn. If looks like hard to extend the outer
barrel (20) ―Open‖ the bleed valve (4) ¼ turns.
11. Install the locking clamp onto the inner barrel (22) if the fitting is
mounted in a position that would allow the retriever outer barrel (20) to
collapse of its own weight.
12. ”Close” the service valve using the service valve extensions handle (7)
(if required). The pressure in the retriever is now confined.
13. ”Bleed-off” retriever pressure. The retriever is still fully pressurized at

this stage and this pressure must be fully relieved.
Warning : WHEN BLEED-OFF RETRIEVER PRESSURE DO NOT STAND

OR PART OF THE BODY AGAINST THE STREAM OF
PRESSURE RELEASE.
Bleed the pressure from the retriever by opening the retriever bleed valve
(4) one or two more turns for gas line. Watch the pressure gauge, a
gradual drop to zero should be indicated, at which point the retriever
should have bleed-off pressure completely. An optional diverter hose
assembly is recommended when bleeding-off retriever pressure, fluids
can be collected in a container and gasses can be diverted to a safe area
away from the operator.
14. Close the bleed valve (4) and disconnect the diverter hose
assembly. When the retriever is completely de-pressurized, disconnect
the diverter hose assembly and close the bleed valve (4).
15. Tap loose the retriever hammer nut (7) using brass hammer and
unscrew fully.
16. Lift the retriever to remove it from the service valve. Do this carefully.
If the product media is a fluid, a certain amount will ooze at the
disconnect junction or from the retriever.
17. Remove the locking clamp. If it was installed on the inner barrel (22)
and collapse the retriever.
18. Check for plug assembly retrieval. At the socket adapter (37) ends of
the retriever, check to see that the plug assembly was removed. The plug
assembly can be unscrewed from the socket adapter pilot (41).
19. Check retriever operation. Stroke the retriever (extend and collapse) if it
seems difficult to operate or feels gritty; rinse the internal with a solvent
(kerosene or varsol). Grease the inner barrel (22) and stroke the retriever.
If it still difficult to operate, feels gritty or friction, strip the retriever before
further use is recommended.
RETRIEVER KIT
PRESSURE GAUGE
BLEED VALVE
SERVICE VALVE
SOCKET ADAPTER
ACCESS FITTING BODY
PIPE LINE
Fig.1. Retriever Kit
4.3 Fitting Corrosion Coupon Holders and Coupons

a. Unscrew and remove the solid plug (2) from the socket adapter pilot
(41).
b. Unscrew and remove the corrosion coupon (7) from the coupon
holders (5). See next standard procedure for handling of coupon.
c. Slack off the anti-vibration set screw (8) using a hex key.
d. Remove the packing nut from the bottom of the solid plug (2) (left
hand thread). Replace any used primary packing (4) and O-ring (3).
e. Replace packing nut with the coupon holder (5) and tighten. Use no
more than one-quarter turn against the primary packing (4) seal.
f. Fit a new anti-vibration set screw (8) and tighten.
g. Assemble the new coupon (7) on the coupon holder (5), ensuring that
the coupon (7) are completely insulated from the mounting screw (6),
nuts and coupon holder (5) by utilizing the insulation and mounting
hardware set (6) provided.
h. 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
(7) – not against the face of the coupon (7) (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.
i. Replace the plug and holder assembly in the fitting as described

below.
Fig 2. Corrosion Coupon Assy
4.4 Fitting Probe Insert and Hollow Plug Nut

a. Unscrew and remove the hollow plug (1) from the socket adapter
pilot (41).
b. 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).
c. Screw the probe 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.
d. Tighten the anti vibration set screw (3&4).
e. Replace the plug (1) and probe (6) assembly in the fitting as
described below. For majority of probe there is no requirement to
orientate the probe 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 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
4.4 Installation Process

The following procedure assumes that the service valve is still installed on
the access fitting body and is in the closed position. The retriever must be in
a cleaned and lubricated condition.
1. Prepare the plug assembly.
a) Visually inspect the plug assembly threads. Clean or repair, if
necessary.
b) Replace used O-ring and packing. If the plug assembly was

previously used, it is recommended that the seals must be replaced.
c) Connect the corrosion-monitoring device to the plug. After initial

packing contact, compress the packing by tightening up to ¼ turn
more. Securely lock into place by tightening set -screw.
d) Index the plug assembly hex. If the corrosion-monitoring device

requires orientating with the product flow, ―index‖ the plug assembly
by filling a notch or marking across the top of the hex. The mark
should be made is that the device is aligned with the product flow.
e) Apply grease sparingly to the full length of the thread on the plug
(only for Solid Plug), primary packing and O-rings.
Notice : DO NOT apply grease to the monitoring device
2. Connect the plug assembly to socket adapter pilot (41). Engage the
plug assembly female thread to the socket adapter pilot (41) male
threads. Screw on the plug assembly to the socket adapter (37). Push the
plug assembly to check that the hex will engage in the socket adapter
(37).
3. Fully extend the retriever and if required install the locking clamp on the
inner barrel (22) and tighten.
4. Connect the retriever to the service valve. First, examine the O-ring (2)
at the hammer nut (7) end of the retriever and replace if nicked, cut or
abraded. Lift the retriever and place it on the service valve, turn the
hammer nut (7) clockwise until the retriever is securely seated and
tightened in place on the service valve. Use the brass hammer to tap a
secure connection.
5. Ensure that the bleed valves are fully “CLOSED”. Even though the
locking clamp may have been installed.
6. Slowly open the service valve by-pass (27) to pressurize the

retriever. Before proceeding further, wait until the retriever is fully
pressurize.
7. Open the service valve ball (12) and close the by-pass valve (27).
8. Remove the locking clamp from the inner barrel (22) and begin
collapsing the retriever. Use a twisting and sliding motion, until the plug
assembly just barely contacts the access fitting body.
9. Engage the plug assembly to the access fitting body.

a) Turn the retriever counter-clockwise for one turn while applying
moderate pressure toward the access fitting. Slowly thread the plug
assembly into the access fitting by turning the retriever outer barrel
(20) clockwise and pushing inward toward the access fitting. If the
plug assembly does not start threading properly, turn the retriever
outer barrel (20) two full turns counter-clockwise. Rotate the outer
barrel (20) clockwise again to engage the threads.
Notice : DO NOT use excessive force and be sure that the

threads engage properly to prevent cross threading.
b) Pull back the retriever to ensure that the pilot (41) has attached, and
then re-engage the hex.
c) If cross threading does occur, remove the retriever and service valve
strictly observing all of the procedures as outline in chapter V. B.
Removing Process. Attach the access fitting body tap assembly. See
special procedure for retriever.
Notice : If any undue resistance is felt in threading the plug, STOP

IMMEDIATELY, back out, remove the plug and clean out the
access fitting using the procedures outlined in special
procedures for retriever.
10. To complete the engagement of the plug assembly to the access

fitting, turn the retriever outer barrel (20) 15 turns. The plug assembly
should be lightly seated. Tighten only ¼ turn after the primary packing
contacts its seat within the access fitting body. This will leave sufficient
adjustment for orientation if necessary using the index mark mentioned
previously.
11. Bleed the retriever. If the operational diverter hose assembly is being
used, it should be connected at this time. Open the bleed valve screw one
or two turns to bleed-off the pressure.
12. Disengage the socket adapter from the plug assembly. Disconnect
the diverter hose assembly, if used. Pull back the outer barrel slightly to
disengage the socket adapter hex. While maintaining this disengagement,
unscrew the socket adapter pilot from the plug assembly by turning
counter-clockwise.
13. Retrievers bleed – off. Extend the retriever fully. Open the retriever
bleed (4) valve and drain the retriever product pressure and media
residue into a container until all pressure has been relieved.
14. Loosen the retriever hammer nut (7) and remove the retriever. Using
the brass hammer. Lift the retriever from the service valve. Do this
carefully if the product media is a fluid because a small amount of product
will also drain from the connection.
15. Loosen the service valve hammer nut (20) and remove the service
valve. Using the brass hammer. Lift the service valve from the access
fitting body. Do this carefully if the product media is a fluid because a
small amount of product will also drain from the connection.
Orientate the plug assembly if required. The index mark filed as
mentioned above must now be aligned to the product flow direction. Turn
the plug assembly hex clockwise until the mark aligns with the flow
direction.
Warning : DO NOT turn the plug assembly hex counter-clockwise

to achieve orientation!
16. Install the stainless steel pipe plug for solid plug assemblies.
Liberally grease ½‖ stainless steel pipe plug and install securely.
17. Prior to installing the protective cover, thoroughly grease the ACME
threads on the access fitting body.
4.5 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.
I. 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 (41). Protect hands while applying grease liberally to the
cutting edges.
2. Connect the retriever. Extend the retriever fully. If the access fitting to
be serviced mounted on the top of line, install locking clamp on the
inner barrel (22) to prevent the retriever outer barrel (20) from
collapsing of its own weight. Lift the retriever and place it on the
service valve. Turn the hammer nut (7) clockwise until retriever is
securely seated tightened in place on the service valve. Use a brass
hammer to make up a secure connection.
3. Open the service valve by-pass (27) then open service valve ball (12).
4. Collapse the retriever, remove the locking clamp and with a twisting,
turning, sliding motion on the retriever outer barrel until the tool just
barely contacts the access fitting body.
5. Turn the retriever outer barrel (20) two full turns counter – clockwise
while applying moderate pressure towards the access fitting. This will
help to allow the tap threads to align with the access fitting threads.
6. For thread tap cutting, slowly turn the retriever outer barrel (20)
clockwise, allowing the tool threads to engage the access fitting, 14 to
17 turns, occasionally turn the retriever outer barrel (20)
counterclockwise to help the tap threads to clear scale or chips from
the tool flutes.
Warning : DO NOT TURN RETRIEVER OUTER BARREL

CLOCKWISE MORE THAN 17 TURNS. IT MAKES
DAMAGED THE ACCESS FITTING.
7. Retrieve the tool. Turn the retriever outer barrel (20) counter
clockwise for about 14 to 17 turns until the tool threads are
disengaged from the internal threads access fitting.
8. Fully extend the retriever. Use a locking clamp as needed.
9. When the tap operation is completed, connect the diverter hose

assembly to the retriever bleed valve (4). Open the retriever bleed
valve (4) and allow bleed - Off for approximately twenty second.
Normally this is sufficient time for debris to be flushed from the access
fitting body threads.
10. Close the retriever bleed valve (4). Remove the diverter hose
assembly.
11. Close the service valve ball (12) and the service valve bleed screw
(22).
12. Bleed and remove the retriever. Open the retriever bleed valve (4)
and allow pressure to bleed off completely. Using the brass hammer,
tap loose and fully unscrew the retriever hammer nut. Lift the retriever
from the service valve.
13. Remove the tap. Unscrew the tap from the socket adapter pilot (41).
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.
II. 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 (41).
2. Connect the retriever. Extend the retriever fully. If the access fitting to
be serviced mounted on the top of line, install locking clamp on the
inner barrel (22). Lift the retriever and place it on the service valve.
Turn the hammer nut (7) clockwise until retriever is securely seated
tightened. Use a brass hammer to make up a secure connection.
3. Open the service valve by-pass (27) then open service valve ball (12).
4. Collapse the retriever, remove the locking clamp and with a twisting,
turning, sliding motion on the retriever outer barrel until the tool just
barely contacts the access fitting body.
5. Brush the threads. Continue the twisting, turning, sliding motion of the
brush, in a clockwise direction, until it bottom.
Warning : Do not turn the brush counter clockwise
6. Retrieve the thread brush service assembly. Beginning with a very

slight clockwise rotation, pull the brush straight up and out of the
access fitting body.
7. Extend the retriever.
8. Close the service valve ball (12) and the service valve by-pass (27).
9. Bleed and remove the retriever. Open the retriever bleed valve (4)
and allow pressure to bleed off completely. Using the brass hammer,
tap loose and fully unscrew the retriever hammer nut (7). Lift the
retriever from the service valve.
10. Remove the thread brush service assembly. Unscrew the tool from
the socket adapter pilot (41).
III. 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.
b) Place hammer nut (20) end of the surge tube assembly on the
service valve. Turn the hammer nut (20) clockwise until the surge
tube assembly is securely seated.
2. Connect diverter hose/high pressure tubing to surge tube bleed valve.
3. Clean the access fitting body.

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

a) Tap looses and fully unscrews the surge tube hammer nut. Lift the
surge tube assembly from the service valve.
IV. 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 and engage the socket adapter pilot (41) to pipe
plug adapter in the same manner as previously described in section
C. no 6 – 7.
4. Pressure balance the retriever

a) Turn the retriever outer barrel (20) slowly counterclockwise, using
the handle to unseat and begin backing off the pipe plug.
b) Retriever pressurization will begin after ½ to 2 turns of outer barrel
(20). Pressurization will be indicated by one of three means :
c) Pressure gauge indicator
d) Hearing the fluid enter the retriever
e) Friction increasing
f) Retriever pressurize balancing is achieved only when the entire
retriever and the operating line are at equal pressure (indicated by
pressure gauge).
5. Retrieving the pipe plug from the plug assembly body.

a) When the retriever has pressure balanced with the line, the pipe
plug can be disengaged from the plug assembly.
b) Turn the retriever outer barrel (20) slowly counterclockwise to
completely disengaged, the pipe plug from the plug assembly.
c) Ensure the pipe plug socket adapter hex and the pipe plug
adapter hex remains engaged during this operation. Disengaged
will allow the socket adapter (37) in the plug assembly.
6. Extend the retriever outer barrel (20).

a) Extend the retriever outer barrel (20) until the pipe plug is
withdrawn fully past the service valve ball.
b) Install the clamp into the inner barrel (22) if the fitting is mounted
in a position to allow the retriever outer barrel (20) to collapse on
its own weight.
7. Close the equalizing valve (27) at service valve and service valve ball
(12).
a) The service valve extension handle (7) (features a slotted and
engages the roll pin of the equalizing valve stem for easy opening
and closing.
b) Close the service ball (12) using the service valve extension
handle (7).
8. Slowly bleed – off retriever pressure (refer to section C. no. 14).
9. Close the bleed valve (4).
10. Loosen the retriever hammer nut (7) by using brass hammer.
11. Lift the retriever from the service valve.
12. Collapse the retriever to expose the socket adapter (37), the attached
pipe plug adapter, and the pipe plug.
13. Remove the adapter and the pipe plug from the socket adapter pilot
(41).
14. Reinstall the retriever on the service valve then pressure balances the
retriever by opening the equalizing valve (27).
15. Remove the plug assemblies (refer to section C. no. 10 – 19).
V. EMERGENCY ACTION IF THE RETRIEVER STUCKED

All procedures describes above have been arranged to minimize
possibility of retriever become stucked, however it is still possible. In such
condition when retriever become stucked, we have to remove plug
assembly in de-pressurize condition. It means that production operator
(production dept.) cooperation is necessary to de-pressurize the line.
If the line can be de-pressurized follow the following procedures.
1. Ensure the line is fully depressurized.
2. Loosing the retriever hammer nut (7) from the service valve by using
brass hammer until fully unscrew.
a) The inner barrel (22) can turn easily, not locked to service valve.
The outer barrel (20) and inner barrel (22) will move together.
3. Remove the solid plug.

a) The socket adapter pilot (41) is still engaged to the plug assembly.
b) Turn the outer barrel (20) / inner barrel (22) counterclockwise
about 14-15 turns. The plug assembly will fully unscrew from
access fitting body.
c) Lift the retriever from the service valve. Do it carefully.
4. Remove the plug assembly and its accessories (coupon or probe)

from the socket adapter pilot (41).
5. Replace the coupons or probes then re-install the plug assembly to

the access fitting body. Refer to section C and D.
6. Report to production operator (production dept.) that the line ready to

be put on service.
a) Wait until the line fully pressurizes.
b) Watch if any leaking found on access fitting. If there is leaking,
possibly the plug assembly does not tightened. Tighten the plug
assembly by turning it clockwise.
7. Retriever can not be used for next retrieving. It must be service with
disassembly. Bring the retriever to workshop for maintenance.
V. Maintenance
5.1 Retriever
The maintenance interval required by either the TKS 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 stroke or turn easily, 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 Part 8.3 or 8.4 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).
5.1.1 Sour Gas Service

On both the TKS 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.
5.1.2 Cleaning and lubricating without disassembly.
1. Extend the retriever until the socket adapter is withdrawn into the inner
barrel by approximately ½ inch. Place the retriever head end down on a
clean surface.
2. Add solvent. Pour approximately one pint (1/2 liter) of solvent into the
retriever inner barrel.
3. Collapse the retriever slowly.
4. Extend the retriever slowly. The solvent while in the process of cleaning
and flushing will remove all lubricant or at least emulsify sufficiently to
make extension of the retriever difficult.
5. Turn the retriever end-for-end. With the retriever head end up, let the
solvent drain out.
6. Repeat steps 1 through 5.
7. Extend the retriever again as indicated in item steps 1. The retriever

head end should again be placed down on a clean surface.
8. Pour SAE 30 weight motor oil into the retriever inner barrel (about four
ounces – 100 grams).
9. Apply grease to the external surface of the retriever inner barrel.
10. Stroke the retriever. Extend and collapse the retriever until the oil and
grease have been adequately filmed on all working surfaces.
11. Test the retriever operation. If the retriever still has a gritty feel and
sound after the stroking procedure indicated above, it must be
disassembled for thorough cleaning and lubricating.
5.1.3 Retriever Disassembly
1. Collapse the retriever.
2. Loosen and remove the mandrel rod stop nut (15). Remove the flat
washer (14).
3. Loosen and remove the four 3/8‖ Allen head screws (1) retaining the
retriever head, using a 5/16‖ Allen wrench.
4. Remove the retriever head (10) and the mandrel rod stop washer (11).
5. Withdraw the mandrel rod (12) from the inner barrel end (22).
6. Loosen or remove the socket adapter (37) assembly if required. The

socket adapter assembly may be left attached or removed from the
mandrel rod (12). To remove, unscrew the two 5/16‖ Allen head cap
screws (43) with a ¼‖ Allen wrench. Slide the socket adapter off the
mandrel rod (12) and revolve its retaining key (35). Remove the socket
adapter pilot (37), spring (39) and flat washer (38) by driving out the
spring pin (40) with a ¼‖ punch.
7. Remove the hammer nut Ext. heavy duty ring (13). Lift the last turn of
the hammer nut retaining lock ring up (13) and out the groove; work
around the ring until the entire ring comes out of its groove in the thread
adapter (8).
8. Loosen and remove the two ¼‖ Allen head screws (26) which retain the
thread adapter (8) by using a 1/8‖ Allen wrench.
9. Remove the thread adapter (8) from the inner barrel (22) by unscrewing
one from the other. Spanner holes are provided in the head end of the
inner barrel (22) and in the sides of the thread adapter (8) to
accommodate the spanner wrench. Remove the hammer nut (7) and
Ext. heavy duty ring (13).
10. Slide seal installation tool over threads of inner barrel (22). If tool is not
available, wrap threads with Teflon tape to protect the outer seal (18)
KOROSI SPECINDO from damage.
11. Loosen and remove the four 3/8‖ Allen head cap screws (1) to remove
the seal stop collar (9).
12. Carefully remove the seal (18) assembly by sliding them over the
protected threads of the inner barrel (22).
13. Stand the retriever in a vertical position with the inner barrel (22) thread
end downward. Push down on the outer barrel (20) until the inner barrel
head end is exposed.
14. Pull the inner barrel (22) out of the outer barrel (20).
15. Remove the seals from the inner barrel (22). It will be necessary to first
remove the four ¼‖ socket head cap screws (19) in the head of the
inner barrel (22). Remove the cap (24) and seal assembly (17) by
carefully prying on side, then the other (23 & 16) with a small slotted
screwdriver.
16. Remove the retriever bleed valve assembly (4) or (33) from the outer
barrel (20). The bleed assembly (4) or (33) can be removed by
unscrewing it from the valve body. The seals on the bleed valve can
also be removed for servicing.
5.1.4 Retriever Assembly
During assembly the working surfaces of the retriever should be inspected

for damage. All metal parts including both barrels (20, 22) should be
cleaned thoroughly by running a cloth soaked in cleaning solution inside

and out. A recommended cleaning solution is five gallon (20 liters) of diesel
fuel, 0.5 pints (250 ml) of motor oil and two tablespoons of methanol mixed
together. A soft brush such as a test tube cleaning brush may be used to
remove any deposits. All seals should be wiped clean. Should the Chrome
surfaces become damage to the point that it no longer seals, the parts will
require replacement.
1. Clean the outer barrel (20) inside surface using a cleaning solvent.
Wipe the bore thoroughly clean and inspect it for damage.
2. Replace the o-ring, back-up rings and seals each time the retriever is
reassembled.
3. Apply grease to about four inches of the bore of the outer barrel (20).
The grease will be filmed thorough out the inside of the retriever when it
is fully assembled and later stroked.
4. Clean the inner barrel (22) using solvent. If the unplate areas of the
inner barrel (22) have been scratched or scored, polish the area with
fine emery cloth. Minor scratches in the chrome can be dressed with
fine crocus cloth. Examine the inner barrel (22) threads and repair as
necessary.
5. Lubricate mandrel seal (16). Press mandrel seal (16) (cup facing
outward) into inner barrel (22) using care not to kink, crimp or roll the
seal. Install seal retainer (23) into inner barrel (22).
Lubricate and install inner seal (17) press inner seal (17) (cup facing
outward) into inner barrel (22), using cares not to damage the seal (17).
Install the cap end (24) into inner barrel (22), insert the four ¼‖ socket
head cap screws (19) through the end cap screw holes and torque to 80
in. lbs.
6. Apply grease to the inside and outside surfaces of the inner barrel (22).
Wrap the thread on the inner barrel with PTFE tape and apply grease in
outside of inner barrel (22) thread.
7. Stand the outer barrel (20) vertically with the bleed valve (4) assembly,
end down. Place the inner barrel (22) thread end first, into the outer
barrel (20). Hold the inner barrel (22) within the outer barrel (20) and
turn the barrels end-for-end. Place a rag under the inner barrel (22)
head end, and push down on the outer barrel (20) until the barrels are
in place.
8. Lubricate outer seal (18) work the seal carefully over the thread (cup
facing thread) until it lies in the thread relief groove of the inner barrel
(22). Install the seal stop collar (9) using the four 3/8‖ Allen head cap
screw (1). DO NOT tighten the screw fully at this time; allow the seal
stop collar (9) to have slight play.
9. Grease and install the o-ring (2) on the thread adapter (8). Install the
back-up ring (3) behind the o-ring (2) and on the same side as the
threads.
10. Install the hammer nut (7) and the ext. heavy duty ring (13) onto the
adapter thread (8).
11. Using the wood clamp, secure the inner barrel (22) and screw on thread
adapter (8) with ‗C‘ pin spanner. Install and tighten the two ¼‖ Allen
head set screw (26) with a 1/8‖ Allen wrench and torque to 70 in. lbs.
12. Install the ext. heavy duty ring (13) onto the thread adapter (8) by
feeding the leading edge into the groove and then working around the
ring.
13. Clean the mandrel rod (12) with solvent. Examine the mandrel rod (12)
for damage. Apply grease liberally to the entire length of the mandrel
rod (12), including the chamfer at the threaded end.
14. Pull the thread adapter (8) until the inner barrel (22) is withdrawn from
the outer barrel (20) and has approximately two inches exposed. Insert
the mandrel rod (12) threaded end first into the inner barrel (22). Gently
push the mandrel rod (12) through the seal.
15. Lay the retriever on its side. Continue pushing the mandrel rod (12) until
the threaded end is exposed from the outer barrel (20) end
approximately one inch. Place the mandrel stop washer (11) onto the
exposed threaded end of the mandrel rod (12).
16. Place the retriever head (10) onto the mandrel rod (12), install the
washer (14) and the stop nut (15).
17. Install the four 3/8‖ Allen head cap screws (1) through the retriever head
screw (10) holes and into the outer barrel (20) screw holes. Torque the
cap screws (1) with a 5/16‖ Allen wrench to 45 ft. lb.
18. Tighten the mandrel rod stop nut (15) with a socket to 110 ft. lb.
19. Torque the four 3/8‖ Allen head cap screws (1) that were initially
installed as indicated in item steps 8 to retain the retriever seal stop
collar (9) to 45 ft. lbs.
20. Install the retriever bleed valve assembly (4) or (33).
21. Position the key in the mandrel rod (12) and reassembly and install the
socket adapter assembly (37) if it was removed. Position the two 5/16‖
cap screws (43) in the third and fifth holes from the socket adapter pilot
end (37) for normal service.
22. Stroke the retriever to ensure it slides easily and does not bind. If the
retriever does bind, loosen the eight 3/8‖ cap screws (1), four at the
head (10) end and four at the seal stop collar (9) end. Stroke the
retriever. Retighten all eight cap screws (1) to 45 ft. lb.; the retriever
should now stroke freely.
5.1 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
* 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.
5.1.1 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).
5.1.2 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.
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).

KS MNL ENG 01 02 (Corr - Monitoring)

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PT.

INSTALLATION, OPERATION & MAINTENANCE

2” SYSTEM CORROSION MONITORING

Rev Date Prepared Checked Approved Description

READ THIS DOCUMENT COMPLETLY BEFORE COMMENCING THE

1. Requirements for protecting the fitting and ensuring usable installation

8‘ (2.4 m) clearance above the top of

2) Set the longitudinal orientation of corrosion monitoring device, by mark across

3) The clearances apply to all orientations.

4) A minimum lateral clearance of 9‖ (230 mm) is required between fitting and

Note: * Only retriever up to 30‖ stroke (full extend position).

NPT A/F SOCKETWELD

Fig.1. Access Fitting

B. Welding of Korosi Specindo Access Fitting

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

2. Determine if air is present, especially in combination with vapors in equipment.

b. Preliminary Job Considerations

2. Obtain the necessary clearance or approvals.

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

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

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

c. Protection Access Fitting during Welding

Welding procedures are the final responsibility of the

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

e. Post Welding Inspection

After welding the following procedures must be followed:

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

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

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

C. Access Fitting Maintenance

N.B.: Hot Tapping should be avoided, if possible, unless it is proved not to be

 A Safety Officer must continuously monitor the task.

Some equipment is unsuitable for Hot Tapping because of metallurgy or thickness

No attempt must be made to Hot Tap atmospheric pressure petroleum storage

A detailed written procedure approved by the Head of Inspection must be prepared

 Bleed off pressure trapped in hot tapping by connect diverter hose

CAUTION: High temperature tap — after each high temperature tap

4.1 Machine Disassembly

f. Remove boring bar through bottom of machine.

4.2 Machine Reassembly

Number of Number of Dimension of Type of Flow

3.2 During Removal

Coupon Observation Appearance Date

3.3 Exposure Time

consistent as practical. Tolerance of 7% allows a variation of 2 days on 30

IV. Storage Maintenance

accessories to be as efficient as possible, and be located at the closest to

6. Probe should be new

4.2 Installation Process

4.3 Setup and Operation

4.3.1 Taking Measurement

4.3.2 Deleting Files

4. Select clear memory command from DCI setup display to reach

4.3.3 Setting the parameter

a. To set up the parameter on the field, apply KSHHU-ER

4.3.4 To download data through KSHHU-ER

4.4 Korosi Specindo Corrosion Monitoring Software (KS-CMS)

4.4.2 Installing KS-CMS

4.4.3 Uninstalling KS-CMS

Environment Protection Box (EPB) recommended connects to earth ground.

DCI (Dx type) is require maintenance because malfunctions as no measurement

1. Ensure that the probe is operational and is not completely corroded.

Note: Wind direction prior to starting operations involving hazardous products.