Installation, Operation & Maintenance Manual

Transcription

1 Original Instructions Installation, Operation & Maintenance Manual Saf-T-Vise STV-HP1 Insertable Tool Holders S-CM-IOM

2 Do not install, maintain, or operate this equipment without reading, understanding, and following the appropriate Sentry Equipment Corp instructions. Otherwise, injury, damage, or both may result. Copyright 2017 by Sentry Equipment Corp. All rights reserved. All product and company names are property of their respective owners. This document contains proprietary information. No part of this document may be photocopied or reproduced without the prior written consent of Sentry Equipment Corp. Limit of Liability Sentry Equipment Corp, its employees, agents, and the authors and contributors to this document specifically disclaim all liabilities and warranties, express or implied (including warranties of merchantability and fitness for a particular purpose), for the accuracy, currency, completeness, and/or reliability of the information contained herein and/or for the fitness for any particular use and/or for the performance of any material and/or equipment selected in whole or part with the user of/or in reliance upon information contained herein. Selection of materials and/or equipment is at the sole risk of the user of this publication. Note The information contained in this document is subject to change without notice. 2 Sentry Equipment Corp

3 Table of Contents Safety Information... 4 General Safety Precautions... 5 General Description... 6 Specifications Saf-T-Vise SVT-HP1 Insertable Tool Holder Specifications... 6 Installation Operation Installation and Retrieval Saf-T-Vise STV-T1 Tool Insertion... 7 Saf-T-Vise STV-T1 Tool Retraction Saf-T-Vise STV-T2 Tool Insertion Saf-T-Vise STV-T2 Tool Retraction Saf-T-Vise STV-T3 Tool Insertion Saf-T-Vise STV-T3 Tool Retraction Maintenance Inspecting the Safety Cap Prepping the Tool Holder for Reinstallation Cleaning the Rod/Probe Shaft Changing a Rod/Shaft and Replacing a Seal Changing a Coupon/Checking Probe End Troubleshooting Leaks Locking Collet Standard Warranty Customer Support Saf-T-Vise STV-HP1 3

4 Safety Information Please read the entire manual before attempting to unpack, set up, or operate this product. Pay careful attention to all Warnings, Cautions, and Notes. Failure to do so could result in serious personal injury and/or equipment damage. Use of Hazard Information If multiple hazards exist, the signal word corresponding to the greatest hazard shall be used. Definitions DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury. WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. CAUTION, used with the safety alert symbol, indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. NOTICE is used to address practices not related to personal injury. Â Information that requires special emphasis. Â TIP Alternate techniques or clarifying information. SHALL: This word is understood to be mandatory. SHOULD: This word is understood to be advisory. 4 Sentry Equipment Corp

5 General Safety Precautions Product Selection, Installation, and Use Improper selection, installation, or use can cause personal injury or property damage. It is solely the responsibility of users, through their own analysis and testing, to select products suitable for their specific application requirements, ensure they are properly maintained, and limit their use to their intended purpose. Follow proper local, state, and federal regulations for proper installation and operational requirements. Always use caution and common sense when working with any chemical. Read the product label and Material Safety Data Sheets (MSDS) carefully and follow the instructions exactly. Potential Equipment Hazards Hot surfaces! This equipment may have very hot surfaces. If an operator contacts a hot surface, injury may occur. Use protective clothing to prevent injury. If other equipment comes in contact with a hot surface, damage to the equipment may occur. Ensure the area around this equipment is kept clear to prevent damage from occurring. High pressures! This equipment may contain fluids at very high pressures. Prior to installing, removing or maintaining this equipment, ensure that the equipment is isolated from all connecting piping, the equipment is depressurized, the contents have been drained, and the equipment is cool. Saf-T-Vise STV-HP1 5

6 General Description The Sentry Saf-T-Vise SVT-HP1 insertable tool holders are multi-functional tools that can be equipped to monitor pipeline corrosion, inject chemical into the process, or sample the pipeline medium. The holders are engineered to specific site applications with a variety of materials and connection styles and sizes. Design pressure and temperature requirements determine the model series and sealing technology of the holder. The holders are designed with a patented locking collet which secures the rod/shaft within the process stream until released by the operator. A process bleeder valve is standard on holders to allow depressurization of the holder after closure of the process isolation valve. The ability to fully retract the rod/shaft out of the pipeline while under pressure allows for pigging without bringing the line down. The standard Saf-T-Vise SVT-HP1 models require the use of an insertion tool. Collet lock bolt Upper body assembly Lower body assembly Indicator button Safety cap Safety cap NPT threads Upper body set screw Bleeder valve Specifications Saf-T-Vise SVT-HP1 Insertable Tool Holder Specifications Maximum allowable operating pressure (MAP) of 5,000 psi at 100 F (344.7 bar at 38 C). : Flanged units have a MAP based on the class of flange used for process line connection and can be rated to a lower MAP. The Teflon seal has a maximum process temperature of 450 F (232.2 C). The graphoil seal has a maximum process temperature of 1000 F (537.8 C). Holder Type: Corrosion Coupon, Atomizer, Sample or Injection Quill. 316/316L SS is the standard material for process wetted components. Connection Style: Flanged or NPT Threaded connection. Standard NPT Connection Sizes: 1/2", 3/4", 1", 1-1/2", or 2". Flange Connection Sizes: Customer specified. (In flanged units, holder is threaded and welded to flange.) Installation Rod/shaft NPT pipeline connection Welded stop The Saf-T-Vise SVT-HP1 tool holders attach to a pipeline isolation valve by means of either a flanged or NPT threaded connection. A holder is installed or removed during the operation and maintenance of the equipment as detailed in the following sections. 6 Sentry Equipment Corp

7 Operation Installation and Retrieval The installation and retrieval methods for the Saf-T-Vise SVT-HP1 tool holders depend upon which insertion tool is used: Saf-T-Vise STV-T1 Insertion Tool Saf-T-Vise STV-T2 Insertion Tool Saf-T-Vise STV-T3 Insertion Tool Read instructions thoroughly before installing or using equipment. Contact your representative or factory customer service if you have any questions. Failure to follow these instructions could result in serious injury or death. Tools needed tape measure permanent marker 12" adjustable wrench anti-seize lubricant torque wrench Teflon tape or paste Saf-T-Vise STV-T1 Tool Insertion The Saf-T-Vise STV-T1 insertion tool may be used for Saf-T-Vise SVT-HP1 coupon holders with rod lengths up to 42 (106.7 cm). Threaded Rod Brass Stem Actuator Wheel Brass Bushing Maintain a firm grip on the Saf-T-Vise STV-T1 insertion tool actuator wheel throughout the insertion procedure, and keep body away from the travel path of the holder rod. An unsecured rod could move outwards forcefully, causing serious injury or death. 1. Close and lock the process isolation valve to prevent incidental opening while installing the unit. 2. Determine desired insertion depth. a. Measure from the top of pipeline isolation valve to the desired zone within the pipeline. TIP Tool compensation: Coupons are generally located ¼ from the bottom of the process line. Set Screw Locking Collet Bolt Rod/Shaft Threaded Tube End Bleeder Valve b. Record measurement for use in step Mark desired insertion depth on rod/shaft. a. Loosen the locking collet bolt on the holder and insert the rod to the fully inserted position. b. Retract the rod until the desired insertion depth is achieved (reference recorded measurement from step 2). Desired insertion depth is measured from the tip of the rod, compensating for attachment (see Tip), to the bottom thread or flange of the body assembly. Saf-T-Vise STV-HP1 7

8 c. Mark the rod with a permanent marker just above the locking collet (above the NPT high pressure insertion tool/ safety cap connecting threads). 4. Secure holder to process line isolation valve connection. a. Retract the marked rod completely into the holder and tighten the locking collet bolt to secure the rod in the holder. b. Apply Teflon tape or paste to the process line isolation valve/holder connection c. Secure the holder to the isolation valve. d. Verify that the locking collet bolt is secure. e. Make sure that the bleeder valve is closed completely. 5. Install Saf-T-Vise STV-T1 insertion tool. a. Place the actuator wheel over the brass stem of the Saf-T-Vise STV-T1 tool housing. b. Turn the actuator wheel counterclockwise to move the brass bushing to the top of the tool. (The threaded rod of the insertion tool will protrude through the actuator wheel.) c. Position the threaded tube end of the Saf-T-Vise STV-T1 tool over the threads of the Saf-T-Vise SVT-HP1 tool holder and tighten onto the tool holder body. d. Tighten brass bushing onto rod adapter. e. Make sure that the brass bushing is flush with the rod and that the process pressure bleeder valve is tightly closed. f. Tighten the locking collet bolt to 35 ft-lb (47.45 Nm). This torque will hold a rod securely up to the design pressure of the unit. g. Tighten set screw. 6. Slowly open the process isolation valve. Check for leaks. If graphoil seal leaks: a. Close isolation valve. b. Slowly open bleeder valve. c. Loosen set screw that secures upper body to lower body. d. Tighten upper body onto lower body; re-tighten set screw. e. Close bleeder valve. f. Resume installation. If Teflon seal leaks: Close isolation valve, relieve pressure with bleeder valve, and contact your representative or factory customer service. 7. Insert rod/shaft into pipeline. a. Loosen the locking collet bolt. b. Turn the actuator wheel clockwise to insert the rod/shaft to the desired depth; use the mark made in step 3 as a reference. c. Tighten the locking collet bolt to 35 ft-lb (47.45 Nm). This torque will hold a rod securely up to the design pressure of the unit. 8. Remove Saf-T-Vise STV-T1 tool. a. Double-check that the locking collet bolt is tight on the rod. b. Loosen set screw on the Saf-T-Vise STV-T1 tool. 8 Sentry Equipment Corp

9 c. Loosen the threaded end of the Saf-T-Vise STV-T1 tool tube and thread the tool off the Saf-T-Vise SVT-HP1 tool holder. Attach safety cap securely to the rod/shaft holder. A loose safety cap can become a projectile and could cause serious injury or death. 9. Install safety cap. a. Place the safety cap over the end of the insertion rod/shaft and thread securely to the holder. TIP If the safety cap is too short to thread securely, or if it engages the red warning indicator, please contact your representative or the factory for assistance. b. Make sure that the red warning indicator remains flush with the end of the safety cap. Saf-T-Vise STV-T1 Tool Retraction The Saf-T-Vise STV-T1 insertion tool may be used for Saf-T-Vise SVT-HP1 coupon holders with rod lengths up to 42 (106.7 cm). Maintain a firm grip on the Saf-T-Vise STV-T1 insertion tool actuator wheel throughout the retraction procedure, and keep body away from the travel path of the holder rod. An unsecured rod could move outwards forcefully, causing serious injury or death. Do not remove the safety cap if the red indicator button on the safety cap is extended. Removal of the safety cap could cause the cap and/or the rod/shaft to move outwards forcefully, causing serious injury or death. 1. Inspect the safety cap before removing. a. If the red indicator button is flush with the safety cap, continue with step 2. b. If the red indicator button is extended, the rod/shaft could be loose. Tighten the locking collet bolt and then test the safety cap. If the cap is hard to remove, the collet is not tightening on the rod/shaft. If the locking collet bolt cannot tighten or if the safety cap is hard to remove, do not continue until the process line is depressurized. If the rod is loose and cannot be tightened, the safety cap should not be removed while the process line is under pressure. 2. Remove safety cap slowly. Set Screw Locking Collet Bolt Threaded Rod Brass Stem Actuator Wheel Brass Bushing Rod/Shaft Threaded Tube End Bleeder Valve 3. Install the Saf-T-Vise STV-T1 tool. a. Make sure that the locking collet bolt is tight on the rod/shaft and that the process pressure bleeder valve is tightly closed. b. Place the actuator wheel over the brass stem of the Saf-T-Vise STV-T1 tool housing. Saf-T-Vise STV-HP1 9

10 c. Turn the actuator wheel counterclockwise to move the brass bushing to the top of the tool. (The threaded rod of the insertion tool will protrude through the actuator wheel.) d. Position the threaded tube end of the Saf-T-Vise STV-T1 tool over the threads of the Saf-T-Vise SVT-HP1 tool holder and tighten onto the holder body. e. Tighten brass bushing onto rod adapter. Make sure bushing is flush with the rod. f. Tighten set screw. 4. Retract rod/shaft from pipeline. a. Hold the actuator wheel firmly and loosen the locking collet bolt. b. Turn the actuator wheel counterclockwise until the rod no longer moves. This indicates that the rod has fully retracted into the body of the tool, past the process isolation valve. c. Slowly close the process isolation valve. If the process isolation valve has difficulty closing, make sure that the rod is completely retracted past the isolation valve. If the rod is stuck, use the Saf-T-Vise STV-T2 or STV-T3 tool to pull the rod. In some instances, the Saf-T-Vise STV-T1 tool might work by pushing it in and then retracting several times to remove the scale. 5. Slowly open the tool bleeder valve, venting the process pressure trapped within the tool. 6. Remove the Saf-T-Vise STV-T1 tool. a. Tighten the locking collet bolt to be hand tight to be sure the rod/shaft will not slip out when removing the tool. b. Slowly open the bleeder valve, venting the process pressure trapped within the holder. c. Turn the actuator wheel counterclockwise to thread the adapter off the end of the insertion rod/shaft. d. Loosen set screw. e. Loosen the threaded end of the Saf-T-Vise STV-T1 tool tube and thread the tool off the Saf-T-Vise SVT-HP1 tool holder. Support the rod/shaft during removal from the process isolation valve to prevent bending. 7. Remove the holder from the process isolation valve. Saf-T-Vise STV-T2 Tool Insertion Maintain a firm grip on the Saf-T-Vise STV-T2 insertion tool hand crank throughout the insertion procedure, and keep body away from the travel path of the rod/shaft. An unsecured rod/shaft could move outwards forcefully, causing serious injury or death. The Saf-T-Vise STV-T2 insertion tool may be used for Saf-T-Vise STV-HP1 tool holders with rod/shaft lengths up to 48" (121.9 cm). 1. Close and lock the process isolation valve to prevent incidental opening while installing the unit. 2. Determine desired insertion depth. a. Measure from the top of pipeline isolation valve to the desired zone within the pipeline. (See Tip.) 10 Sentry Equipment Corp

11 TIP Tool compensation: Coupons are generally located ¼ in (6.35 mm) from the bottom of the process line, atomizers are located in the upper 1/3 of the line, and quills are placed in the middle 1/3 of the process line. b. Record measurement for use in step Mark desired insertion depth on rod/shaft. a. Loosen the locking collet bolt on the holder and insert the rod/shaft to the fully inserted position. b. Retract the rod/shaft until the desired insertion depth is achieved (reference recorded measurement from step 2). Desired insertion depth is measured from the tip of the rod, compensating for attachment (see Tip), to the bottom thread or flange of the body assembly. c. Mark the rod/shaft with a permanent marker just above the locking collet (above the NPT high pressure insertion tool/safety cap connecting threads). 4. Secure holder to process line isolation valve connection. a. Retract the marked rod/shaft completely into the holder and tighten the locking collet bolt to secure the rod/ shaft in the holder. b. Apply Teflon tape or paste to the process line isolation valve/holder connection. c. Secure the holder to the isolation valve. d. Verify that the locking collet bolt is secure. 5. Install the Saf-T-Vise STV-T2 insertion tool. a. Remove the support handle from the storage area at the top of the tool and thread it into the handle position on the side of the base. If brand new, remove acorn nut on hand crank and remove hand crank assembly (be sure not to lose key on shaft). Flip assembly to allow for turning, and thread acorn nut back on. b. Turn the Saf-T-Vise STV-T2 tool hand crank counterclockwise until the travel plate is flush with the top plate. c. Align the groove openings of the brass swivel joint and the housing to allow installation of the rod/shaft into the insertion tool. d. Install the rod/shaft into the swivel joint and tighten swivel joint onto holder s threads. e. Reposition the holder so swivel joint groove aligns with housing opening. f. Quills, flat coupon holders, and 90-degree atomizers are marked with a directional arrow near the top of the shaft. If applicable, align the arrow so that the rod/shaft is oriented appropriately for the pipeline flow (see Tip). g. Use the hand crank to move the travel plate down far enough that the rod/shaft threads are fully exposed through the travel plate. h. Remove the retrieval bushing nut from the storage set screw on the top plate and thread it onto the end of the rod, securing the rod/shaft to the insertion tool. i. Tighten the locking collet bolt to 35 ft lb (47.45 Nm) and make sure that the bleeder valve is closed completely. Travel Plate Hand Crank Bleeder Valve Storage Set Screw Top Plate Retrieval Bushing Nut Support Handle Brass Swivel Joint Collet Lock Bolt Saf-T-Vise STV-HP1 11

12 TIP Aligning arrows: Injection quill: align arrow with pipe on downstream side. Sample quill: align arrow with pipe on upstream side. Flat coupon holder: align arrow with pipe on either the up or downstream side. 90-degree adapters with bete nozzles: align arrow with pipe on downstream side. 6. Insert rod/shaft into pipeline. a. Hold the hand crank firmly throughout the insertion. b. Open the process isolation valve slowly. Check for leaks. If graphoil seal leaks: a. Close isolation valve. b. Slowly open bleeder valve. c. Loosen set screw that secures upper body to lower body. d. Tighten upper body onto lower body; re-tighten set screw. e. Close bleeder valve. f. Resume installation. If Teflon seal leaks: Close isolation valve, relieve pressure with bleeder valve, and contact your representative or factory customer service. c. Loosen the locking collet bolt. d. Use the hand crank to insert the rod/shaft to the desired depth; use the mark made in step 3 as a reference. e. Tighten the locking collet bolt to 35 ft-lb (47.45 Nm). This torque will hold a rod/shaft securely up to the design pressure of the unit. 7. Remove Saf-T-Vise STV-T2 tool. a. Verify that the locking collet bolt is tightened to 35 ft lb (47.45 Nm). b. Remove the retrieval bushing nut from the end of the rod/shaft and thread it onto the storage set screw on the top plate of the insertion tool. c. Turn the Saf-T-Vise STV-T2 tool hand crank counterclockwise until the travel plate is past the top of the rod/shaft. If the rod/shaft retracts with the travel plate when you turn the hand crank counterclockwise, then the locking collet is not functioning properly. Contact your representative or Sentry customer service before continuing. d. Hold on to the insertion tool to prevent it from falling as you loosen the brass swivel joint from the holder s threads. e. Align the groove openings of the brass swivel joint and the housing to allow removal of the insertion tool. Attach safety cap securely to the rod/shaft holder. A loose safety cap can become a projectile and could cause serious injury or death. 8. Install safety cap. a. Place the safety cap over the end of the insertion rod/shaft and thread securely to the holder. b. Make sure that the red warning indicator remains flush with the end of the safety cap. 12 Sentry Equipment Corp

13 If the safety cap is too short to thread securely, or if it engages the red warning indicator, please contact your representative or the factory for assistance. Saf-T-Vise STV-T2 Tool Retraction The Saf-T-Vise STV-T2 insertion tool may be used for Saf-T-Vise STV-HP1 insertable tool holders with rod/shaft lengths up to 48" (121.9 cm). Maintain a firm grip on the Saf-T-Vise STV-T2 insertion tool hand crank throughout the retraction procedure, and keep body away from the travel path of the rod/shaft. An unsecured rod/shaft could move outwards forcefully, causing serious injury or death. Do not remove the safety cap if the red indicator button on the safety cap is extended. Removal of the safety cap could cause the cap and/or the rod/shaft to move outwards forcefully, causing serious injury or death. 1. Inspect the safety cap before removing. a. If the red indicator button is flush with the safety cap, continue with step 2. b. If the red indicator button is extended, the rod/shaft could be loose. If the rod/shaft is loose and cannot be tightened, the safety cap should not be removed while the process line is under pressure. Tighten the locking collet bolt and then test the safety cap. If the cap is hard to remove, the collet is not tightening on the rod/shaft. If the locking collet bolt cannot tighten or if the safety cap is hard to remove, do not continue until the process line is depressurized. 2. Remove safety cap slowly. 3. Install the Saf-T-Vise STV-T2 insertion tool. a. Remove the support handle from the storage area at the top of the tool and thread it into the handle position on the side of the base. If brand new, remove acorn nut on hand crank and remove hand crank assembly (be sure not to lose key on shaft). Flip assembly to allow for turning, and thread acorn nut back on. b. Turn the Saf-T-Vise STV-T2 tool hand crank counterclockwise until the travel plate is flush with the top plate. c. Align the groove openings of the brass swivel joint and the housing to allow installation of the rod/shaft into the insertion tool. d. Install the rod/shaft into the swivel joint and tighten swivel joint onto holder s threads. Travel Plate Hand Crank Bleeder Valve Storage Set Screw Top Plate Retrieval Bushing Nut Support Handle Brass Swivel Joint Collet Lock Bolt Saf-T-Vise STV-HP1 13

14 e. Reposition the holder so swivel joint groove aligns with housing opening. f. Use the hand crank to move the travel plate down far enough that the rod/shaft threads are fully exposed through the travel plate. g. Remove the retrieval bushing nut from the storage set screw on the top plate and thread it onto the end of the rod, securing the rod/shaft to the insertion tool. h. Make sure that the bleeder valve is closed completely. 4. Retract the rod/shaft from the pipeline. a. Hold the hand crank firmly throughout the retraction. b. Loosen the locking collet bolt. c. Turn the crank counterclockwise until the crank will no longer turn. This indicates that the tool has fully retracted into the body of the tool, past the process isolation valve. d. Slowly close the process isolation valve. If the process isolation valve has difficulty closing, make sure that the rod/shaft is completely retracted past the isolation valve. e. Slowly open the bleeder valve on the rod/shaft holder to vent the process pressure trapped within the holder. 5. Remove the Saf-T-Vise STV-T2 tool. a. Tighten the locking collet bolt to hand tight so the rod/shaft will not slip out when removing the tool. b. Remove the retrieval bushing nut from the end of the rod/shaft and thread it onto the storage set screw on the top plate of the insertion tool. c. Turn the Saf-T-Vise STV-T2 tool hand crank counterclockwise until the travel plate is past the top of the rod/shaft. d. Hold on to the Saf-T-Vise STV-T2 tool to prevent it from falling as you loosen the brass swivel joint from the tool holder s threads. e. Align the groove openings of the brass swivel joint and the housing to remove the Saf-T-Vise STV-T2 tool. Support the rod/shaft during removal from the process isolation valve to prevent bending. 6. Remove the tool holder from the process isolation valve. Leave the bleeder valve open to relieve pressure in the event the process valve leaks. 14 Sentry Equipment Corp

15 Saf-T-Vise STV-T3 Tool Insertion The Saf-T-Vise STV-T3 insertion tool is designed to insert rods/shafts that are longer than 48" (121.9 cm). Note that the Saf-T-Vise STV-T3 tool will work for any Saf-T-Vise SVT-HP1 tool holder regardless of length. Maintain a firm grip on the Saf-T-Vise STV-T3 insertion tool hand crank throughout the insertion procedure, and keep body away from the travel path of the rod/shaft. An unsecured rod/shaft could move outwards forcefully, causing serious injury or death. 1. Close and lock the process isolation valve to prevent incidental opening while installing the unit. 2. Determine desired insertion depth. a. Measure from the top of pipeline isolation valve to the desired zone within the pipeline. TIP Tool compensation: Coupons are generally located ¼" from the bottom of the process line, atomizers are located in the upper 1/3 of the line, and quills are placed in the middle 1/3 of the process line. b. Record measurement for use in step Mark desired insertion depth on rod/shaft. a. Loosen the locking collet bolt on the holder and insert the rod/shaft to the fully inserted position. b. Retract the rod/shaft until the desired insertion depth is achieved (reference recorded measurement from step 2). Desired insertion depth is measured from the tip of the rod, compensating for attachment (see Tip), to the bottom thread or flange of the body assembly. c. Mark the rod/shaft with a permanent marker just above the locking collet (above the NPT high pressure insertion tool/safety cap connecting threads). 4. Secure holder to process line isolation valve connection. a. Retract the marked rod/shaft completely into the holder and tighten the locking collet bolt to secure the rod/shaft in the holder. b. Apply Teflon tape or paste to the process line isolation valve/holder connection. c. Secure the holder to the isolation valve. d. Verify that the locking collet bolt is secure. Support Handle Locking Collet Bolt Top Plate Support Handle Storage Area Travel Plate Insertion Collet Assembly Hand Crank Brass Swivel Joint Bleeder Valve 5. Install the Saf-T-Vise STV-T3 insertion tool. a. Remove the support handle from the storage area at the top of the tool and thread it into the handle position on the side of the base. If brand new, remove acorn nut on hand crank and remove hand crank assembly (be sure not to lose key on shaft). Flip assembly to allow for turning, and thread acorn nut back on. b. Turn the Saf-T-Vise STV-T3 tool hand crank counter-clockwise until the travel plate is either flush with the top plate or only as high as it is possible to safely access the bolts once tool is on the holder. Saf-T-Vise STV-HP1 15

16 c. Remove the insertion collet assembly located on the travel plate by removing the two (2) collet assembly fasteners. Next, remove the front collet, making sure not to lose either collet. d. Align the groove openings of the brass swivel joint and the housing to allow installation of the rod/shaft into the insertion tool. e. Install the rod/shaft into the swivel joint and tighten swivel joint onto holder s threads. f. Reposition the holder so swivel joint groove aligns with housing opening. g. Quills, flat coupon holders, 90-degree atomizers are marked with a directional arrow near the top of the shaft. If applicable, align the arrow so that the rod/shaft is oriented appropriately for the pipeline flow. TIP Aligning arrows: Injection quill: align arrow with pipe on downstream side. Sample quill: align arrow with pipe on upstream side. Flat coupon holder: align arrow with pipe on either the up or downstream side. 90-degree adapters with bete nozzles: align arrow with pip on downstream side. h. Using the hand crank, adjust the position of the travel plate to the desired height. i. Insert the rod/shaft into the groove for the collet assembly as well as the groove on the top plate. j. Re-install the insertion collet assembly by installing the collet onto the rod/shaft. Secure the two (2) collet assembly fasteners to the travel plate. k. Tighten the locking collet bolt on the Saf-T-Vise STV-T3 tool to 35 ft lb (47.45 Nm) and make sure that the bleeder valve is closed completely. 6. Insert rod/shaft into pipeline. Collet Assembly Fasteners Maintain a firm grip on the insertion tool hand crank throughout the insertion procedure, and keep body away from the travel path of the rod/shaft. An unsecured rod/shaft could move outwards forcefully, causing serious injury or death. a. Open the process isolation valve slowly. Check for leaks. If graphoil seal leaks: a. Close isolation valve. b. Slowly open bleeder valve. c. Loosen set screw that secures upper body to lower body. d. Tighten upper body onto lower body; re-tighten set screw. e. Close bleeder valve. f. Resume installation. If Teflon seal leaks: Close isolation valve, relieve pressure with bleeder valve, and contact your representative or factory customer service. b. Loosen the locking collet bolt on the holder only, and use the hand crank to insert the rod/shaft. c. For rods/shafts longer than 48" (121.9 cm), multiple insertions are needed. To make an additional insertion of the tool: 16 Sentry Equipment Corp

17 Bring the travel plate to the bottom of the Saf-T-Vise STV-T3 tool and tighten the locking collet bolt on the holder to 35 ft-lb (47.45 Nm). Loosen the insertion collet on the Saf-T-Vise STV-T3 tool, move the draw bar up as high as you can safely reach, and then tighten the collet on the Saf-T-Vise STV-T3 tool to 35 ft-lb (47.45 Nm). Loosen the locking collet bolt on the holder, turn the crank, and move the draw bar and shaft down as far as it will go or until desired depth is achieved. Tighten the collet on the holder and repeat insertions as needed until the desired depth is achieved. d. Tighten the locking collet bolt on the holder to 35 ft-lb (47.45 Nm). This torque will hold a rod/shaft securely up to the design pressure of the unit. 7. Remove Saf-T-Vise STV-T3 tool. a. Remove the insertion collet assembly from the travel plate on the Saf-T-Vise STV-T3 tool by removing the two (2) collet assembly fasteners. b. Hold on to the Saf-T-Vise STV-T3 tool to prevent it from falling as you loosen the brass swivel joint from the holder s threads. c. Unthread the brass swivel joint from the holder and align the groove openings of the brass swivel joint and the housing to allow removal of the Saf-T-Vise STV-T3 tool. Attach safety cap securely to the rod/shaft holder. A loose safety cap can become a projectile and could cause serious injury or death. 8. Install safety cap. a. Place the safety cap over the end of the insertion rod/shaft and thread securely to the holder. If the safety cap is too short to thread securely, or if it engages the red warning indicator, please contact your representative or the factory for assistance. b. Make sure that the red warning indicator remains flush with the end of the safety cap. Saf-T-Vise STV-T3 Tool Retraction The Saf-T-Vise STV-T3 insertion tool is designed to insert rods/shafts that are longer than 48" (121.9 cm). Note that the Saf-T-Vise STV-T3 tool will work for any Saf-T-Vise SVT-HP1 tool holder regardless of length. Maintain a firm grip on the Saf-T-Vise STV-T3 insertion tool hand crank throughout the retraction procedure, and keep body away from the travel path of the rod/shaft. An unsecured rod/shaft could move outwards forcefully, causing serious injury or death. Do not remove the safety cap if the red indicator button on the safety cap is extended. Removal of the safety cap could cause the cap and/or the rod/shaft to move outwards forcefully, causing serious injury or death. 1. Inspect the safety cap before removing. a. If the red indicator button is flush with the safety cap, continue with step 2. b. If the red indicator button is extended, the rod/shaft could be loose. Saf-T-Vise STV-HP1 17

18 Tighten the locking collet bolt and then test the safety cap. If the cap is hard to remove, the collet is not tightening on the rod/shaft. If the locking collet bolt cannot tighten or if the safety cap is hard to remove, do not continue until the process line is depressurized. If the rod/shaft is loose and cannot be tightened, the safety cap should not be removed while the process line is under pressure. 2. Remove safety cap slowly. 3. Install the Saf-T-Vise STV-T3 insertion tool. a. Remove the support handle from the storage area at the top of the tool and thread it into the handle position on the side of the base. If brand new, remove acorn nut on hand crank and remove hand crank assembly (be sure not to lose key on shaft). flip assembly to allow for turning, and thread acorn nut back on. b. Turn the Saf-T-Vise STV-T3 tool hand crank counter-clockwise until the travel plate is flush with the top plate. c. Remove the insertion collet assembly located on the travel plate by removing the two (2) collet assembly fasteners. Next, remove the front collet, making sure not to lose either collet. d. Align the groove openings of the brass swivel joint and the housing to allow installation of the rod/shaft into the insertion tool. e. Install the rod/shaft into the swivel joint and tighten swivel joint onto holder s threads. f. Reposition the holder so swivel joint groove aligns with housing opening. g. Quills, flat coupon holders, and 90-degree atomizers are marked with a directional arrow near the top of the shaft. If applicable, align the arrow so that the rod/shaft is oriented appropriately for the pipeline flow. TIP Aligning arrows: Injection quill: align arrow with pipe on downstream side. Sample quill: align arrow with pipe on upstream side. Flat coupon holder: align arrow with pipe on either the up or downstream side. 90-degree adapters with bete nozzles: align arrow with pip on downstream side. h. Using the hand crank, adjust the position of the travel plate to the desired height. i. Insert the rod/shaft into the groove for the insertion collet assembly as well as the groove on the top plate. j. Re-install the insertion collet assembly by installing the insertion collet onto the rod/shaft. Secure the two (2) collet assembly fasteners to the travel plate. k. Tighten the insertion collet bolt on the Saf-T-Vise STV-T3 tool to 35 ft lb (47.45 Nm) and make sure that the bleeder valve on the holder is closed completely. 4. Retract rod/shaft from pipeline. Collet Assembly Fasteners Maintain a firm grip on the Saf-T-Vise STV-T3 insertion tool hand crank throughout the retraction procedure, and keep body away from the travel path of the rod/shaft. An unsecured rod/shaft could move outwards forcefully, causing serious injury or death. 18 Sentry Equipment Corp

19 a. Hold the hand crank firmly throughout the retraction. b. Loosen the locking collet bolt on the holder only. c. Turn the hand crank counterclockwise until the travel plate is either flush with the top plate of the retraction tool or as high as you can safely reach. d. For rods longer than 48" (121.9 cm), multiple retractions will be needed. To make another retraction of the tool: Bring the travel plate flush to the top plate of the tool. Tighten the locking collet bolt on the holder to 35 ft lb (47.45 Nm). Loosen the insertion collet on the draw bar, move the draw bar down as far as possible, and then tighten the collet on the Saf-T-Vise STV-T3 tool to 35 ft lb (47.45 Nm). Loosen the collet on the holder, turn the crank to move the draw bar and shaft up as far as you can safely reach, then tighten the collet on the holder to 35 ft lb (47.45 Nm). Repeat until the tool is completely retracted into the body. e. Slowly close the process isolation valve. If the process isolation valve has difficulty closing, make sure that the rod/shaft is completely retracted past the isolation valve. f. Slowly open the tool bleeder valve, venting the process pressure trapped within the tool. 5. Remove Saf-T-Vise STV-T3 insertion tool. a. Remove the insertion collet assembly from the travel plate on the Saf-T-Vise STV-T3 tool by removing the two (2) collet assembly fasteners. TIP Each insertion collet assembly is unique to each retrieval tool, be sure to keep the removed assembly with the specific tool retractor. b. Hold on to the Saf-T-Vise STV-T3 tool to prevent it from falling as you loosen the brass swivel joint from the holder s threads. c. Align the groove openings of the brass swivel joint and the housing to allow removal of the Saf-T-Vise STV-T3 tool. Support the rod/shaft during removal from the process isolation valve to prevent bending. 6. Remove the holder from the process isolation valve. Leave the bleeder valve open to relieve pressure in the event the process valve leaks. Saf-T-Vise STV-HP1 19

20 Maintenance All maintenance procedures assume the Saf-T-Vise SVT-HP1 insertable tool holder has been properly removed from the line. See retraction section for the appropriate insertion tool for instructions. Inspecting the Safety Cap Remove safety cap from holder and ensure the red indicator is still in good condition. If the indicator is faded, brittle, or missing, return the cap to the factory for indicator repair. Prepping the Tool Holder for Reinstallation After each use the tool holder threads should be checked and cleaned. Tools needed Clean rag Pick or small screwdriver Teflon tape or paste Anti-seize lubricant 1. Use a small pick or screwdriver to remove Teflon tape from the threads of the holder and the isolation valve connection threads. 2. After tape and debris are removed, wipe down the threads with a clean rag. 3. Reapply Teflon tape and anti-seize lubricant to the holder threads. Cleaning the Rod/Probe Shaft The rod/probe shaft should be cleaned each time the tool holder is removed from the line. This helps prevent buildup on the rod/shaft and damage to the seal. Tools needed Clean rag Cleaner/solvent 320 grit sand paper or other finer grit paper Medium crescent wrench Molykote 55 lubricant or other fine viscosity lubricant 1. Remove the holder from the line. 2. Loosen the locking collet bolt and slide the rod/shaft to the fully inserted position (until the stop hits the top of the body). Leave the locking collet loose so the rod/shaft can be spun inside the body. 3. Clean the exposed rod/shaft with 320 grit or finer sand paper using a rotational motion. 4. When the exposed rod/shaft is cleaned of external debris, wipe the rod/shaft with a clean rag and solvent to remove any leftover debris. 5. Slide the rod/shaft to the fully retracted position and repeat the steps above to clean the remaining rod/shaft. 6. When the rod/shaft is thoroughly clean, wipe the rod/shaft with Molykote 55 lubricant or other fine viscosity lubricant. 20 Sentry Equipment Corp

21 Changing a Rod/Shaft and Replacing a Seal Tools needed Medium crescent wrench Permanent marker ¼" NPT nipple 2" 4" (5 10 cm) in length (for atomizers or quills only) Hex key set Small pick or screwdriver Clean rag Seal Installation Tool (for Teflon seals only) P/N E for 3/8" OD rod/shaft P/N F for ¼" OD rod/shaft New seal for holder (Teflon or graphoil as needed) Molykote 55 lubricant or other fine viscosity lubricant Anti-seize lubricant 320 grit or finer sandpaper Cleaner/solvent 1. Remove the rod/shaft. a. With the holder removed from the line, loosen the locking collet and slide the rod/shaft to the fully inserted position, leaving 1" (2.5 cm) between the top of the holder and the adapter lock nut. b. Tighten the locking collet bolt to 35 ft-lb (47.45 Nm). c. Remove adapter. Coupon holder only: If using a flat coupon, use a permanent marker to mark the rod to show where the orientation arrow points on the shaft (reference the arrow at the top of the shaft). Use a medium crescent wrench to loosen the adapter lock nut. Remove both the adapter and the lock nut. Atomizer shaft or quill shaft: With a permanent marker, mark the rod to show where the orientation arrow points on the shaft (reference the arrow at the top of the shaft). If fluid inlet does not have wrench flats, use a ¼" NPT nipple threaded into the fluid inlet adapter to remove the adapter from the shaft. If the adapter has a fluid inlet assembly, you can use the existing assembly to aid in removal. d. Loosen the collet and slide the shaft out of the body of the holder. 2. Separate the upper and lower body of the holder a. Use a hex key to loosen (but not completely remove) the small set screw on the upper body. Make sure the set screw is loose. Failure to loosen the set screw can cause permanent damage to the holder. b. With the set screw loose, remove the upper body. If the upper body is difficult to remove, stop immediately and make sure that the set screw is loose. 3. Replace the seal. a. With the upper body removed, use a pick or small screwdriver to gently pick out the old seal. Saf-T-Vise STV-HP1 21

22 b. Clean the seal body of the holder with a clean rag. c. Insert new seal: For Teflon seal: Place the new Teflon seal onto the seal insertion tool with the seal opening facing away from the handle. Lubricate the open-faced edge of the seal with Molykote 55 or other fine viscosity lubricant by placing a dot of lubricant on your finger, then slowly rolling your finger around the outside lip of the seal, completely coating the outside edge. Insert the Teflon seal into the holder body by pushing the tool and seal straight into the body of the holder. Make sure the seal tool is straight with the holder to ensure you do not side load the seal. Remove the seal tool. For graphoil seal: Insert the graphoil seal directly into the holder body. Make sure you push the seal straight into the body of the holder to avoid side loading the seal. 4. Reassemble the holder. a. Apply a small amount of anti-seize lubricant to the lower body threads where the upper body threads on. Do not tighten the set screw until the upper and lower body of the holder are properly aligned. Tightening the set screw on the threads will permanently damage the tool. b. Loosen the set screw enough to allow for easy assembly. c. Thread the upper body of the holder onto the lower body. For Teflon seal: Tighten the upper body until it is snug against the lower body. Tighten set screw. For graphoil seal: Do not tighten the set screw until after installation of the rod/shaft. Thread, but do not tighten the upper body down to the lower body. When using a graphoil seal, tightening the upper body without a rod/shaft in the holder will damage the seal and prevent insertion of the rod/shaft. 5. (Re)Install the rod/shaft. a. Clean the rod/shaft before installing. If reinstalling a used rod/shaft, thoroughly clean the rod/shaft with 320 grit or finer sandpaper using a rotational motion, then wipe the rod/shaft with a clean rag and solvent to remove any leftover debris. If installing a new rod/shaft, wipe the new rod/shaft down with solvent and a clean rag to remove any debris. b. Add a small amount of Molykote 55 or other fine lubricant to the rod/shaft c. Wrap the threaded end of the rod/shaft with two (2) complete wraps of Teflon tape to protect the seal during rod/shaft insertion. d. Place the rod/shaft into the holder carefully. If the rod/shaft cannot pass through the body, make sure the locking collet is loose and oriented in the correct direction (dot on top). It is sometimes easier to completely remove the locking collet from the body. Be careful not to lose collet. 22 Sentry Equipment Corp

23 Each insertion collet assembly is unique to each retrieval tool. Be sure to keep the removed assembly with the specific tool retractor. e. Once the rod/shaft is through the body of the holder, reinstall the locking collet (if removed) with the orientation dot facing the top of the tool, and tighten the collet. f. Remove the protective Teflon tape from the rod/shaft. g. For atomizer or quill shaft only, reapply new Teflon tape (2 3 wraps is adequate). Coupon holder rods do not need Teflon tape. 6. Finish reassembly. For coupon holder rods only a. Move rod/shaft through tool so the last 1.5 inches are visible out the top of the holder. b. Tighten the locking collet bolt to 35 ft-lb (47.45 Nm). c. Reinstall the adapter and lock nut securely on the rod. d. If using a graphoil seal, gently tighten the upper body onto the lower body, and then tighten the set screw. If using graphoil seal, do not overtighten the upper body. This will make the rod/shaft difficult to move and cause excessive wear on the seal. e. The tool is now ready to go back into service. For atomizer or quill shafts a. Add a very small amount of anti-seize lubricant to the shaft end (take special care not to get any anti-seize lubricant in the shaft as this could clog your nozzle tip). b. Thread the fluid adapter onto the shaft and tighten the adapter using the small ¼" nipple (or fluid inlet assembly) if no wrench flats are present. c. If re-installing a used shaft, tighten down to the mark made earlier. If installing a new shaft, align the mark on the fluid adapter with the outlet of the atomizer tip or quill. d. If using graphoil a seal, gently tighten the upper body onto the lower body, and then tighten the set screw. e. The tool is now ready to go back into service. Changing a Coupon/Checking Probe End Tools needed Clean rag Cleaner/solvent 320 grit sand paper or other finer grit paper Medium crescent wrench Molykote 55 lubricant or other fine viscosity lubricant Flat tip screwdriver 1. Remove tool holder from the process pipeline by following instructions for specific insertion tool. 2. Remove old coupon or inspect the rod/shaft as needed. 3. Clean the rod/probe shaft. 4. If using a coupon holder, attach the new coupon. 5. Reinstall the tool holder into the pipeline by following instructions for specific insertion tool. Saf-T-Vise STV-HP1 23

24 Troubleshooting Leaks Fluid Inlet Assembly Leaks 1. Isolate and bleed down the pressure, and attempt to tighten the leak point. If leak persists, continue with next step. 2. Re-tape the fittings on the fluid inlet assembly. a. Remove the entire holder from the process line. b. Remove the fluid inlet assembly from the holder. c. Disassemble and remove all the old Teflon tape from fluid inlet assembly and then re-tape the fittings. d. Reassemble the fluid inlet assembly using a small amount of anti-seize lubricant on each fitting. Do not overtighten the fittings as this can cause a leak point. e. If leak persists, continue with the next step. 3. If the leak persists at a particular point, close the isolation valve, relieve pressure with bleeder valve, and contact your representative or factory customer service. Seal Leaks Teflon Seal: If the holder is leaking from the top of the holder body where the rod/shaft and body meet, the Teflon seal is damaged and requires replacement. See section on Seal Replacement on page 21. Graphoil Seal: If the holder is leaking from the top of the holder body where the rod/shaft and body meet, the graphoil seal is most likely loose. 1. Adjust the top body to tighten the seal. a. Loosen the small set screw on the upper body. b. Using a crescent wrench on the top body wrench flats, turn the upper body clockwise in 1/4-turn increments until the leak stops. c. Turn the upper body an additional 1/4 turn clockwise. d. Re-tighten the small set screw on the upper body to prevent the body from loosening. e. If leak persists, the graphoil seal is damaged and requires replacement. See section on Seal Replacement on page 21. Connection Leaks 1. If the holder leaks from any threaded portion, immediately isolate the holder from the line and remove process pressure. 2. Remove the holder from the isolation valve. 3. Follow the procedure for Prepping a Holder for Reinstallation. This procedure can be used for all connection points on a holder including the fluid inlet assembly, probe shaft adapters, bleeder valves, and any other connections that may be on the holder. Bleeder Valve Leaks If the holder leaks from the bleeder valve outlet or bleeder valve stem, the bleeder valve is damaged and should be replaced. Contact the factory to order a replacement valve. 24 Sentry Equipment Corp

25 Locking Collet Not locking shaft in place If the locking collet fails to lock the rod/shaft in place with 35 ft lb (47.45 Nm) of torque applied to the collet locking bolt, the locking collet is damaged and must be replaced. Please contact the factory to order a replacement. Do not interchange collets between tool holders. Collets are specially machined for each tool holder individually and cannot be interchanged. Collet repair must be performed by the factory. Rod/shaft marred by collet 1. Check collet orientation. If the collet has an orientation indicator dot (see photo), the indicator dot must always face toward the top of the holder. Collets without the indicator dot are not dependent on orientation. a. If the collet is upside down, remove the locking collet bolt from the holder and gently tap the holder on a hard surface to remove the collet. b. Reinstall the collet with the orientation indicator dot facing toward the top of the holder, and then reinstall the locking collet bolt. 2. Check the collet for wear. A worn collet will not distribute pressure evenly on the rod/shaft and may cause damage. If the collet is worn, the entire holder must be replaced immediately. Collets are matched to a body assembly during manufacturing and cannot be replaced separately. Standard Warranty Sentry Equipment Corp ( Seller ) warrants products manufactured by it and supplied hereunder ( Products ) to be free from defects in workmanship and, to the extent materials are selected by Seller, to be free from defects in materials, in each case for a period as defined in the table below: Brand Product Line Warranty Period Sentry Steam & Water Sampling Products and Systems Solid & Powder Sampling Products and Systems Gas Sampling Products and Systems Eighteen months from date of shipment or twelve months from startup (whichever occurs first) Liquid & Slurry Sampling Products and Systems Corrosion Monitoring Products Waters Equipment Steam & Water Sampling Products and Systems Twelve months from date of shipment To view the full warranty, go to Saf-T-Vise STV-HP1 25