COSASCO®

CHEMICAL INJECTION SYSTEM

ACCESS FITTING ASSEMBLIES
Model 50 Flarweld CI

Cosasco high pressure chemical injection fittings allow

safe, controlled, and easy injection under full operating
pressure, dramatically reducing downtime. Cosasco
offers a wide range of delivery options from standard
NPT to robust flanged side tees for chemical injection
into high pressure systems.

A variety of injection tubes, quills, and nozzles can

be used to provide the most efficient delivery and
dispersion for a given application. A Cosasco Retriever
and Service Valve are used to safely install and retrieve
injection and sampling components under operating
conditions that need to be replaced due to a change in
injection requirements or if maintenance is necessary.

The Flarweld type Chemical Injection Access Fitting is

designed to be welded directly to the pipe or vessel.
The fitting incorporates a radius to match the curvature
of the pipe or vessel, with a maximum 1/16” weld gap.
It also incorporates a thick body to provide adequate
branch reinforcement area to help strengthen the weld
joint.

Chemical Injection Access Fitting Temperature and Pressure Ratings

Mounting — Flarweld with Integral Branch Standard Temperature Rating with Viton/Teflon Seals:
Reinforcement per ASME B31.3 — From -15° F (-26° C) Up To +400° F (+204° C)
Direct welding to pipe or vessel, most economical, most Available Temperature Rating with Optional Seals:
compact — From -70° F (-56° C) Up To +450° F (+232°C)
NPT (std.), Socketweld, Buttweld, and Flanged Tee Con- Pressure Rating — 6000 PSI / 41.3 MPa Working
nections Higher pressure rating available. Please consult Cosasco
Representative.
Robust Design
Access Under Pressure — Maintenance or removal Options
under full operating pressure Available with ACME Threaded Internal Configurations
Injection/Sampling Components available in highly Various injection tubes, quills, and nozzles available
corrosion resistant alloys
Safely inject a wide variety of chemicals Standards
Meets NACE MR0175 and MR0103
Canadian Registration (CRN) and Conformity to
Pressure Equipment Directive (PED)
 50 Flarweld Chemical Injection

Ordering Information for a Typical Access Fitting Arrangement

A complete chemical injection monitoring point consists of several parts. Depending on your particular requirements, one option
should be chosen from each ordering table to make up a complete arrangement.

Table 1: Chemical Injection Access Fitting Assembly Consists of:

1. Access Fitting with Side Tee for Injection Line
2. Solid Plug Assembly
3. Pressure Retaining Cover
Table 2: Injection/Sampling Nut Assembly
Table 3.1 - 3.6: Injection/Sampling Tubes/Nozzles
Table 4 & 5: Nipples & Shut-Off Valves

Pressure
Solid Plug Retaining Cover
Assembly (Table 1)
(Table 1)
Injection/Sampling
Nut Assembly
(Table 2)
Chemical Injection
Access Fitting
(Table 1)
Nipple and
Shutoff Valve
(Table 4 & 5)

Tube/Nozzle
(Table 3.1-3.6)

Chemical Injection Access Fitting Weights and Dimensions

Weight* Height
Body Style
lbs. Inches Height
1/4” Tee 6.5 5.25 (Inches)
1/2” Tee 7.0 6.25
3/4” Tee 7.0 6.25
1” Tee 7.75 7.25

*Weight provided for NPT/Socketweld Side Tee Options

The addition of a tee adds between 1 and 3 inches to the height of the standard access fitting according to the tee size and type.
 50 Flarweld Chemical Injection

Access Fitting Options

Side Tee Connection Options (standard NPT, shown on previous page)

Socketweld Side Tee Buttweld Side Tee Flanged Side Tee

Internal ACME Threaded (AT) Access Fittings Assemblies

Cosasco ACME Threaded (AT) access fittings have internal female ACME
threads that receive either a solid or hollow male ACME threaded plug.
The ACME Threaded access fittings are advantageous in applications where
the process contains solids and debris. Access Fittings that are mounted
bottom-of-line are especially susceptible to solids getting lodged in the
threads of the plug assembly. ACME threads have courser threads with a
larger pitch and a narrower angle than standard v-threads. See individual
data sheet for more details and ordering information.

Access Fitting with Internal Acme Threads

High Pressure Retaining Covers and Protective Sleeves (highly

recommended for all Access Fitting Assemblies)
Cosasco high pressure retaining covers with pressure gauge and bleed plug
offer a secondary pressure isolation with a pressure rating of up to 10,000
PSI. A viton o-ring creates a tight seal retaining any pressure that may build
up. The bleed plug allows pressure accumulation verification prior to the
cover being backed off. The pressure gauge is used to indicate if there is
any pressure build up.

High Pressure Retaining Cover

Service Kits
Routine servicing of access fittings is integral to ensure safe installation and retrieval of corrosion monitoring and chemical injection
devices. Cosasco highly recommends the solid carrier plug to be replaced after three insertions or if damaged. A primary packing
should be replaced after every service, and for a solid carrier plug, the secondary O’ ring seal; for an injection nut, the injection
nut seals, if they are excessively worn or damaged. Cosasco Care Service kits provide the necessary replacement parts for routine
maintenance of each access fitting location.
 50 Flarweld Chemical Injection

1. Chemical Injection Access Fitting Assembly

Chemical Injection Fittings have a side tee that incorporates a ¼”, ½”, ¾”, or 1”
NPT threaded inlet on the side of the fitting body, with optional Socketweld,
Buttweld, and Flanged inlet to suit the type of injection connection.

Table 1– Ordering Information

Model High Pressure Chemical Injection Access Fitting Assembly
50 Flarweld Mounting
50AT Flarweld Mounting – Acme Threaded
Code Plug Assembly – Enter code for plug type from options below
Type (1st Digit) Alloy Mat’l (2nd Digit) Packing Seal (3rd Digit)
0 Not Req. 0 Not Req. 0 Not Req.
1 Solid 1 316/316L S.S. 1 Viton O-Ring Teflon Primary Packing - * -15 to 400° F (-26 to 204°C)
3 Hastelloy C-276 2 Ethylene Propylene O-Ring Vespel Primary Packing - * -70 to 250°F (-56 to 121°C)
4 Nitronic 60 3 Kalrez O-Ring Vespel Primary Packing - * -15 to 450°F (-26 to 232°C)
5 Carbon Steel 4 No O-Ring Nitronic 60 Primary Packing - * -50 to 450°F (-45 to 232°C)
6 Inconel 625 5 Hydrin O-Ring Teflon Primary Packing - * -40 to 275°F (-40 to 135°C)
XXX 7 2205 Duplex S.S. 6 Nitrile O-Ring Teflon Primary Packing - * -30 to 250°F (-35 to 121°C)
7 Ethylene Propylene O-Ring, Teflon Primary Packing - * -70 to 250°F (-56 to 121°C)
8 EDR Viton O-Ring Teflon Primary Packing - * -15 to 400° F (-26 to 204°C)
9 Kalrez O-Ring Teflon Primary Packing - * -15 to 450° F (-26 to 232°C)
A HNBR EOL 101 O-Ring Teflon Primary Packing - * -13 to 320° F (-25 to 160° C)
B HNBR EOL 985 O-Ring Teflon Primary Packing - * -67 to 302° F (-55 to 150° C)
C AFLAS 69/90 O-Ring Teflon Primary Packing * 32 to 392° F (0 to 200° C)
D Viton “B” (VB185-70) Teflon Primary Packing * 15 to 400° F (-26 to 204°C)
Code Side Tee Size
1 1/4” Tee
2 1/2” Tee
3 3/4” Tee
4 1” Tee
Code Optional Side Tee Configuration (omit for standard NPT)
SW Socketweld Tee
FL71 150# RF
FL72 300# RF
FL73 4/600# RF
FL74 9/1500# RF
FL75 2500# RF Flanged Side Tee configurations available for ½”, ¾” & 1” sizes only.
FL40 150# RJ
FL41 300# RJ
FL42 4/600# RJ
FL43 9/1500# RJ
FL44 2500# RJ
BW40 Schedule 40 (Standard) Buttweld Tee
BW80 Schedule 80 (Extra Strong) Buttweld Tee
BW160 Schedule 160 (Not applicable for ¼”) Buttweld Tee Required for 6000 PSI locations.
BWXX Schedule XX (Double Extra Strong) (Not applicable for ¼”) Buttweld Tee
Code Pipeline Size
02 2”
03 3”
04 4”
06 6”
10 8-10”
18 12-18”
36 20-36”
FL Flat
Code Body Material
K03504 ASTM A105 Carbon Steel
K03011 ASTM A350 LF2 Carbon Steel
G10220 AISI 1018 - 1022 Carbon Steel
S31600 AISI 316 Stainless Steel
S31803 Duplex Stainless Steel (Nitronic 60 Plug Recommended)
N06625 Inconel 625
Code Secondary Pressure Retaining Covers**
10 Pressure Retaining Cover with Bleed Plug & Pressure Gauge P/N 740090 10,000 PSI max.

50 111 2 SW 02 K03504 10 Example

* Nominal Temperature Range
**Optional materials, seals, and pressure gauges are available. See ordering information on next page for details.
 50 Flarweld Chemical Injection

Pressure Retaining Covers

Material, Seal, and Pressure Gauge Ordering Options for Pressure Retaining Cover
Model Pressure Retaining Cover
740090 Pressure Retaining Cover With Bleed Plug, Pressure Gauge
Code Body Material
XXXXXX Enter UNS Number (omit for standard A350-LF2 Carbon Steel)
Code Seal Material Option (omit for standard Viton)
1 Viton
2 Ethylene Propylene
3 Kalrez
5 Epchlorohydrin
6 Nitrile
8 EDR Viton
A HNBR EOL 101 O-Ring Teflon Primary Packing - * -13 to 320˚F (-25 to 160˚C)
B HNBR EOL 985 O-Ring Teflon Primary Packing - * -13 to 320˚F (-25 to 160˚C)
C AFLAS 36/90 O-Ring Teflon Primary Packing - * 32 to 392˚F (0 to 200˚C)
Code Pressure Gauge Range
YYYY Enter Pressure (psi) (omit for standard 6000 psi gauge on 740090)

740090 S31600 1 4000 Example

Ordering Options as Part of an Access Fitting Assembly

Pressure Retaining Covers:
-10/XXXXXX/Y/YYYY

Pressure Gauge Range
Seal Material Option
Cover Material UNS Number

Pressure Gauge

Bleed Plug

O-Ring
 50 Flarweld Chemical Injection

2. Injection/Sampling Nut Assembly

An injection nut assembly is required to connect the injection tube to the solid plug assembly of the access fitting. The part number
and length of the injection nut assembly is determined by the access fitting body height. This is, depending upon application, a
multiple-use nut that replaces the nut of the Solid Plug Assembly in the Access Fitting Assembly. Its function is to direct the injection
product to the Injection Tube or directly to the atomization device. The Injection/Sampling Nut has bleed ports in the side wall above
an access fitting body bore o-ring seal; and is drilled and tapped with 1/4", 1/2”, 3/4 NPT threads to enable attachment of different
size Injection/Sampling Tubes or Nozzle Assemblies.

Table 2 – Ordering Information

Select Part Number from first table and then options from second table for complete part number.
Nut Size Access Fitting Body Height
NPT Length 5.25” 6.25” 7.25” 8.25”
1/4” 1.75 120603
1/4” 2.75 204728
1/4” 3.75 122217
1/4” 5.50 120556
1/2” 1.75 120604
1/2” 2.75 204899
1/2” 3.75 122219
1/2” 5.50 120552
3/4” 1.75 N/A
3/4” 2.75 204900
3/4” 3.75 122220
3/4” 5.50 120406

Part Number
Code Material* (Omit for 316/316L S.S.)
S31803 Duplex Stainless Steel
S32760 Super Duplex Stainless Steel
Code O-Ring Material (Omit for standard Viton O-Ring Material (V894-90))
2 Ethylene Propylene O-Ring (E540-80)
3 Kalrez O-Ring (3018)
5 Hydrin O-Ring (Z4)
6 Nitrile O-Ring (N674-70)
8 Viton (EDR) O-Ring (V1238-95)
A HNBR EOL 101 O-Ring
B HNBR EOL 985 O-Ring
C AFLAS 69/90 O-Ring
D Viton “B” O-Ring (VB185-70)
Code Integral Check Valve (not available for PN 120603 or 120604, 1.75” length)
CV Integral Check Valve included (omit for no CV)

122217 S31803 2 CV Example

*Consult Factory for materials not specified above.

Injection Nut Accessories

Part Number Description
209871-W Injection Nut Seal Kit (1 O-ring, 2 Back-Up Rings (Teflon))
209871-W-CV Injection Nut Seal Kit (1 O-ring, 2 Back-Up Rings (Teflon), and Check Valve Seals)
124900 Set Screw (316 S.S.)
 50 Flarweld Chemical Injection

3. Injection/Nozzles/Sampling Tubes (For sizing information see last page)

Depending upon the application an Injection Tube or Sampling Tube may be selected. The Injection Tube is the pathway for the
injected product flowing from the Injection Nut to the process. Standard Cosasco Injection Tubes are offered in 1/4", 1/2”, and 3/4”
NPT sizes to mate with like size NPT Injection Nuts.
Note: For high velocity process conditions it is recommended that Wake Frequency Calculations be performed – please contact a
Cosasco representative for further details.

Scarf and Quill Injection Tube (1/4”,1/2”, 3/4” NPT)

This style is similar to the open NPT Injection Tube but has a scarf and quill cut instead of a plain open end. It utilizes the turbulence
created by its design, in conjunction with the natural turbulence within the pipe or vessel, to accomplish distribution of the injected
product into the product process flow. Its injection is oblique or parallel (depending upon ID placement) to the pipeline product flow.

Features and Benefits

• Typically used for moderate to fast flow

• 1/4”, 1/2”, 3/4” NPT connection

• Reliable and even chemical dispersion when center-of-line

• No restricting orifice and consequently no backpressure

nor pressure differential is experienced at the injection
tube orifice.

• Virtually clog proof even for unscreened inhibitors

• Easy maintenance

Table 3.1 – Ordering Information

Part Number Description
6300 2” Injection Tube 1/4 NPT x Quill (316 S.S. only)
630002 2” Injection Tube 1/4 NPT x Quill
630021 2” Injection Tube 1/2 NPT Sch 160 x Quill (316 S.S. only)
630023 2” Injection Tube 1/2 NPT x Quill
630024 2” Injection Tube 1/2 NPT Sch XXS x Quill (316/L S.S. only)
630020 2” Injection Tube 3/4 NPT x Quill
Code Material*
S31600/S31603 316/L Stainless Steel
S31803 Duplex Stainless Steel
S32760 Super Duplex Stainless Steel
Code Order Length
LL.LL Length in 1/4” increments from 1.25 to 36.00 inches.

630002 S31803 10.00 Example

*Consult Factory for materials not specified above.
 50 Flarweld Chemical Injection

Injection Tube x Head with Atomization Nozzle (9/16” Head)

This Injection Tube has 9/16” male NPT end which accommodates a selection of 9/16” female NPT nozzles for perpendicular
Injection/Atomization. The injection dispersion is always parallel with the product flow and is the usual style used for center-of-line
injection. For ordering select Injection Tube from Table 3.2a and Atomization Nozzle from Table 3.2b below.

Features and Benefits

• 1/4” and 1/2” NPT connection
• Injection dispersion always parallel to
product flow

• Typically used for center-of-line injection

• Spray angle 80 psi –35° to 300 psi – 91°

• Gallons per hour capacity: 0.3 gal at 40 psi to

130 gal at 1000 psi.
Injection Tube x Head with
Atomization Nozzle

Table 3.2a – Ordering Information

Part Number Description
6304 2” Injection Tube 1/4 NPT x Head (9/16”)
630570 2” Injection Tube 1/2 NPT x Head (9/16”)
Code O-ring Material (omit for standard Viton (V894-90))
2 Ethylene Propylene O-Ring (E540-80)
3 Kalrez O-Ring (3018)
5 Hydrin O-Ring (Z4)
6 Nitrile O-Ring (N674-70)
8 Viton (EDR) O-Ring (V1238-95)
A HNBR EOL 101 O-Ring
B HNBR EOL 985 O-Ring
C AFLAS 69/90 O-Ring
D Viton “B” O-Ring (VB185-70)
Code Material* (Omit for 316/316L S.S.)
S31803 Duplex Stainless Steel
S32760 Super Duplex Stainless Steel
Code Order Length
LL.LL Length in 1/4” increments from 1.25 to 36.00 inches.

6304 2 S31803 10.00 Example

*Consult Factory for materials not specified above.
 50 Flarweld Chemical Injection

Atomization Nozzle (Cap with Core (9/16”))

A male Cap with Core is typically threaded into the head. Cap with Core selection is made based on the combination of desired flow
rate and differential pressure (pressure difference between the process pipeline pressure and the injection pipeline pressure). See
chart below for selection.

Table 3.2b – Ordering Information

Cap with Core (9/16”)
Part Orifice Nom. GPH Capacity* @ PSI Differential Spray Angle (°)
Number Dia. (in.)
40 60 80 100 200 300 500 700 1000 40 80 300
psi psi psi psi psi psi psi psi psi psi psi psi
*129490 0.016 0.3 0.36 0.42 0.48 0.67 0.82 1.1 1.3 1.5 51
*129473 0.016 0.4 0.48 0.56 0.64 0.9 1.1 1.4 1.7 2.0 58
743036 0.016 0.5 0.63 0.72 0.81 1.1 1.4 1.8 2.1 2.5 63

*129472 0.016 0.6 0.72 0.84 0.95 1.3 1.6 2.1 2.5 3.0 35 65
129475 0.020 1.0 1.2 1.4 1.6 2.2 2.7 3.5 4.2 5.0 45 62 72
129483 0.020 1.5 1.8 2.1 2.4 3.4 4.1 5.3 6.3 7.5 65 70 72
129474 0.028 2.0 2.4 2.8 3.2 4.5 5.5 7.1 8.4 10.0 70 75 77
200865 0.039 2.0 2.4 2.8 3.2 4.5 5.5 7.1 8.4 10.0 165 158
129381 0.028 3.0 3.7 4.2 4.7 6.7 8.2 10.6 12.5 15.0 65 70 73
200866 0.039 3.0 3.7 4.2 4.7 6.7 8.2 10.6 12.5 15.0 157 152
200867 0.042 4.0 4.9 5.8 6.3 8.9 11.0 14.1 16.7 20.0 72 81 84
200868 0.060 4.0 4.9 5.8 6.3 8.9 11.0 14.1 16.7 20.0 156 155
128330 0.042 6.0 7.3 8.6 9.5 13.4 16.4 21.0 25.0 30.0 73 79 81
200869 0.060 8.0 9.8 11.3 12.6 17.9 22.0 28.0 33.0 40.0 85 89 91
200870 0.060 8.0 9.8 11.3 12.6 17.9 22.0 28.0 33.0 40.0 152 153
200871 0.064 10.0 12.2 14.4 15.8 22.0 27.0 35.0 42.0 50.0 82 84 86
200215 0.076 12 14.7 17.4 19.0 27.0 33.0 42.0 50.0 60.0 78 82 85
128333 0.076 14.0 17.1 20.0 22.0 31.0 38.0 49.0 59.0 70.0 85 88 90
743037 0.086 16.0 19.6 22.7 25.0 36.0 44.0 57.0 67.0 80.0 83 86 88
200872 0.076 18.0 22.0 26.0 28.0 40.0 49.0 64.0 75.0 90.0 81 84 86
743038 0.081 20.0 24.0 28.4 32.0 45.0 55.0 71.0 84.0 100.0 75 78 80
200873 0.076 22.0 27.0 31.0 35.0 49.0 60.0 78.0 92.0 110.0 70 72 75
128395 0.086 26.0 32.0 36.5 41.0 58.0 71.0 92.0 109.0 130.0 73 74 77

* Those grayed out flow options mean that the flow rate will be achieved, however the flow performance (hollow cone spray pattern and angle) are
not guaranteed, nor can they be estimated.
** Those grayed out angle options mean that the flow performance (hollow cone spray pattern and angle) are not guaranteed, nor can they be
estimated.

Flow Rate Determination

For approximate flow rate determination with a differential pressure not stated above (and over 40 psi) see equation on last page.
 50 Flarweld Chemical Injection

Injection Tube x Head with Atomization Nozzle (1/4” Head)

This Injection Tube has 1/4” male NPT end which accommodates a selection of 1/4” female NPT nozzles for perpendicular Injection/
Atomization. The injection dispersion is always parallel with the product flow and is the usual style used for center-of-line injection.
For ordering select Injection Tube from Table 3.3a and PJ Atomization Nozzle from Table 3.3b below.

Features and Benefits

• 1/2” NPT connection
• Finest fog of any direct pressure nozzle
• Cone-shaped fog spray pattern
• 90° spray pattern. For best 90° pattern
operate nozzle at or above 60 psi
• Flow rates from 0.013 to 1.4 gpm
Injection Tube with
PJ Atomization Nozzle

Table 3.3a – Ordering Information

Part Number Description

630573 2” Injection Tube 1/2 NPT x Head (1/4”) [For use with 632906 PJ Nozzle only-See chart below]

Code O-ring Material (omit for standard Viton (V894-90))

2 Ethylene Propylene O-Ring (E540-80)
3 Kalrez O-Ring (3018)
5 Hydrin O-Ring (Z4)
6 Nitrile O-Ring (N674-70)
8 Viton (EDR) O-Ring (V1238-95)
A HNBR EOL 101 O-Ring
B HNBR EOL 985 O-Ring
C AFLAS 69/90 O-Ring
D Viton “B” O-Ring (VB185-70)
Code Material
S31600/S31603 316/L Stainless Steel
S31803 Duplex Stainless Steel
S32760 Super Duplex Stainless Steel
Code Order Length
LL.LL Length in 1/4” increments from 1.25 to 36.00 inches.

630573 2 S31600 10.00 Example

 50 Flarweld Chemical Injection

PJ Atomization Nozzle
A PJ atomization nozzle is typically threaded into the head. PJ atomization nozzle selection is made based on the combination of
desired flow rate and coverage area. See chart below for selection.

“A”
“H”

1/4” MNPT
“B”
“Coverage D”

Fog PJ with polypropylene filter Fog Pattern

Table 3.3b – Ordering Information

PJ Atomization PJ Flow Rates and Dimensions*

Impingement, 90° Spray Angle, 1/8” OR 1/4” Sizes, BSP or NPT**

Gallons per Minute @ PSI Differential

Male
Nozzle Nozzle Approx.
Part Pipe K Approx. Approx. Approx.
No. No. Spray Pipe
Number Size Factor 10 psi 30 psi 40 psi 50 psi 60 psi 80 psi 100 psi 200 psi 400 psi Orifice Coverage Dim. (in.)
(-Z) (Desc) Height Size
(-Y) Dia. (in.) (inches) D A B
H (in.)

1 PJ6 0.00095 0.006 0.007 0.008 0.010 0.013 0.019 0.006 10 5

2 PJ8 0.00180 0.013 0.014 0.016 0.018 0.025 0.036 0.008 10 5

3 PJ10 0.00269 0.017 0.019 0.021 0.024 0.027 0.038 0.054 0.010 10 5

4 PJ12 0.00364 0.023 0.026 0.028 0.033 0.036 0.051 0.073 0.012 10 5

5 PJ15 0.00585 0.032 0.037 0.041 0.045 0.052 0.059 0.083 0.117 0.015 10 5
632906 1/4 1/4 0.97 0.56
(-2)
6 PJ20 0.0106 0.034 0.058 0.067 0.075 0.082 0.095 0.11 0.15 0.21 0.020 12 6

7 PJ24 0.0158 0.050 0.087 0.10 0.11 0.12 0.14 0.16 0.22 0.32 0.024 16 8

8 PJ28 0.0206 0.065 0.11 0.13 0.15 0.16 0.18 0.21 0.29 0.41 0.028 18 9

9 PJ32 0.0285 0.090 0.16 0.18 0.20 0.22 0.25 0.28 0.40 0.57 0.032 22 11

10 PJ40 0.0443 0.14 0.24 0.28 0.31 0.34 0.40 0.44 0.63 0.89 0.040 24 12

632906 2 4 Example

* Dimensions are approximate. Check with Cosasco for critical dimension applications.
**Spray angle performance varies with pressure. Contact Cosasco for specific data on critical applications.
 50 Flarweld Chemical Injection

Fine Spray Nozzles (Injection Tube with Nozzle (Female))

This Injection Tube has 1/4” male NPT end which accommodates a selection of 1/4” female NPT nozzles for perpendicular Injection/
Atomization. For ordering select Injection Tube from Table 3.4a and Fine Spray Nozzle from Table 3.4b below.

Features and Benefits

• 1/4”, 1/2”, 3/4” NPT connection

• Spray angle 80 psi –35° to 300 psi – 91°

• Gallons per hour capacity: 0.3 gal at 40 psi

to 130 gal at 1000 psi.

• Produce very small drops and delivers a very

fine spray using liquid pressure only – no
compressed air required
Injection Tube with
• Choice of spray angles and spray patterns Atomization Nozzle

Table 3.4a – Ordering Information

Part Number Description
6302 2” Injection Tube 1/4 NPT x 1/4 NPT (316 S.S.)
Code Material*
S31600/S31603 316/L Stainless Steel
S31803 Duplex Stainless Steel
S32760 Super Duplex Stainless Steel
Code Order Length
LL.LL Length in 1/4” increments from 1.25 to 36.00 inches.

6302 S31600 10.00 Example

*Consult Factory for materials not specified above.
 50 Flarweld Chemical Injection

1/4” Nozzle (Female)

A nozzle is typically connected to the injection tube opposite the end connected to the injection nut. Nozzle selection is made based
on the combination of desired flow rate and differential pressure*. See chart below for selection. Injection is perpendicular to the
pipeline product flow.
* This is the pressure difference between the process pipeline pressure and the injection pipeline pressure.

Table 3.4b – Ordering Information

1/4” Nozzle (Female)

GPH Capacity* Spray Angle (°)**

Part Orifice @ PSI Differential
Number Nom. Dia.
40 psi 60 psi 80 psi 100 psi 200 psi 300 psi 500 psi 700 psi 1000 40 psi 80 psi 300
(in.)
psi psi
200904 0.016 0.3 0.36 0.42 0.48 0.67 0.82 1.1 1.3 1.5 51
200905 0.016 0.4 0.48 0.56 0.64 0.9 1.1 1.4 1.7 2.0 58
743039 0.016 0.5 0.63 0.72 0.81 1.1 1.4 1.8 2.1 2.5 63
200906 0.016 0.6 0.72 0.84 0.95 1.3 1.6 2.1 2.5 3.0 35 65
200907 0.020 1.0 1.2 1.4 1.6 2.2 2.7 3.5 4.2 5.0 45 62 72
200908 0.020 1.5 1.8 2.1 2.4 3.4 4.1 5.3 6.3 7.5 65 70 72
200909 0.028 2.0 2.4 2.8 3.2 4.5 5.5 7.1 8.4 10.0 70 75 77
200910 0.039 2.0 2.4 2.8 3.2 4.5 5.5 7.1 8.4 10.0 165 158
200911 0.028 3.0 3.7 4.2 4.7 6.7 8.2 10.6 12.5 15.0 65 70 73

200912 0.039 3.0 3.7 4.2 4.7 6.7 8.2 10.6 12.5 15.0 157 152
200913 0.042 4.0 4.9 5.8 6.3 8.9 11.0 14.1 16.7 20.0 72 81 84
200914 0.060 4.0 4.9 5.8 6.3 8.9 11.0 14.1 16.7 20.0 156 155
200915 0.042 6.0 7.3 8.6 9.5 13.4 16.4 21.0 25.0 30.0 73 79 81
200916 0.060 8.0 9.8 11.3 12.6 17.9 22.0 28.0 33.0 40.0 85 89 91
200917 0.060 8.0 9.8 11.3 12.6 17.9 22.0 28.0 33.0 40.0 152 153
200918 0.064 10.0 12.2 14.4 15.8 22.0 27.0 35.0 42.0 50.0 82 84 86
200919 0.076 12 14.7 17.4 19.0 27.0 33.0 42.0 50.0 60.0 78 82 85
200920 0.076 14.0 17.1 20.0 22.0 31.0 38.0 49.0 59.0 70.0 85 88 90
743040 0.086 16.0 19.6 22.7 25.0 36.0 44.0 57.0 67.0 80.0 83 86 88
200921 0.076 18.0 22.0 26.0 28.0 40.0 49.0 64.0 75.0 90.0 81 84 86
743041 0.081 20.0 24.0 28.4 32.0 45.0 55.0 71.0 84.0 100.0 75 78 80
200922 0.076 22.0 27.0 31.0 35.0 49.0 60.0 78.0 92.0 110.0 70 72 75
200923 0.086 26.0 32.0 36.5 41.0 58.0 71.0 92.0 109.0 130.0 73 74 77

* Those grayed out flow options mean that the flow rate will be achieved, however the flow performance (hollow cone spray pattern and angle) are not guaranteed,
nor can they be estimated.
** Those grayed out angle options mean that the flow performance (hollow cone spray pattern and angle) are not guaranteed, nor can they be estimated.

Flow Rate Determination

For approximate flow rate determination with a differential pressure not stated above (and over 40 psi) see equation on last page.
 50 Flarweld Chemical Injection

Flush Spray Nozzle (Male)

This nozzle threads directly into the Injection Nut Assembly to provide spray injection flush with the pipe wall when the correct injection nut is used.

Features and Benefits

• 1/4” NPT connection

• Hollow cone spray pattern

• Allows for pigging operations without removing

any system component parts

• Spray angle 80 psi –35° to 300 psi – 91°

• Gallons per hour capacity: 0.3 gal at 40 psi to Injection Nut with
130 gal at 1000 psi. Flush Nozzle

Table 3.5 – Ordering Information

1/4” NPT Flush Nozzle (Male)
Part Orifice GPH Capacity* @ PSI Differential Spray Angle (°)**
Number Nom.
40 psi 60 psi 80 psi 100 psi 200 psi 300 psi 500 psi 700 psi 1000 psi 40 psi 80 psi 300 psi
Dia. (in.)
129183 0.016 0.3 0.36 0.42 0.48 0.67 0.82 1.1 1.3 1.5 51
201020 0.016 0.4 0.48 0.56 0.64 0.9 1.1 1.4 1.7 2.0 58
743042 0.016 0.5 0.63 0.72 0.81 1.1 1.4 1.8 2.1 2.5 63
201021 0.016 0.6 0.72 0.84 0.95 1.3 1.6 2.1 2.5 3.0 35 65
201022 0.020 1.0 1.2 1.4 1.6 2.2 2.7 3.5 4.2 5.0 45 62 72
201023 0.020 1.5 1.8 2.1 2.4 3.4 4.1 5.3 6.3 7.5 65 70 72
201024 0.028 2.0 2.4 2.8 3.2 4.5 5.5 7.1 8.4 10.0 70 75 77
201025 0.039 2.0 2.4 2.8 3.2 4.5 5.5 7.1 8.4 10.0 165 158
201026 0.028 3.0 3.7 4.2 4.7 6.7 8.2 10.6 12.5 15.0 65 70 73
201027 0.039 3.0 3.7 4.2 4.7 6.7 8.2 10.6 12.5 15.0 157 152
201028 0.042 4.0 4.9 5.8 6.3 8.9 11.0 14.1 16.7 20.0 72 81 84
201029 0.060 4.0 4.9 5.8 6.3 8.9 11.0 14.1 16.7 20.0 156 155
201030 0.042 6.0 7.3 8.6 9.5 13.4 16.4 21.0 25.0 30.0 73 79 81
201031 0.060 8.0 9.8 11.3 12.6 17.9 22.0 28.0 33.0 40.0 85 89 91
201032 0.060 8.0 9.8 11.3 12.6 17.9 22.0 28.0 33.0 40.0 152 153
201033 0.064 10.0 12.2 14.4 15.8 22.0 27.0 35.0 42.0 50.0 82 84 86
201034 0.076 12 14.7 17.4 19.0 27.0 33.0 42.0 50.0 60.0 78 82 85

201035 0.076 14.0 17.1 20.0 22.0 31.0 38.0 49.0 59.0 70.0 85 88 90
743043 0.086 16.0 19.6 22.7 25.0 36.0 44.0 57.0 67.0 80.0 83 86 88
201036 0.076 18.0 22.0 26.0 28.0 40.0 49.0 64.0 75.0 90.0 81 84 86
743044 0.081 20.0 24.0 28.4 32.0 45.0 55.0 71.0 84.0 100.0 75 78 80
201037 0.076 22.0 27.0 31.0 35.0 49.0 60.0 78.0 92.0 110.0 70 72 75
201038 0.086 26.0 32.0 36.5 41.0 58.0 71.0 92.0 109.0 130.0 73 74 77
* Those grayed out flow options mean that the flow rate will be achieved, however the flow performance (hollow cone spray pattern and angle) are not guaranteed,
nor can they be estimated.
** Those grayed out angle options mean that the flow performance (hollow cone spray pattern and angle) are not guaranteed, nor can they be estimated.

Flow Rate Determination

For approximate flow rate determination with a differential pressure not stated above (and over 40 psi) see equation on last page.
 50 Flarweld Chemical Injection

Sampling Tube
A multiple use tube allowing for either injection or sampling; no atomization or dispersion device is attached. The natural turbulence
within the pipeline or vessel is relied upon to accomplish even distribution. Standard sampling tubes are offered in 1/4”, 1/2”, and
3/4” NPT sizes to mate with like size NPT injection nuts.

Features and Benefits

• Perpendicular injection

• 1/4”, 1/2”, 3/4” NPT connection

• No restricting orifice, therefore no pressure differential is

experienced at the orifice
• Supports basic chemical feed and sampling services

• Easy maintenance

Table 3.6 – Ordering Information

Part Number Description
6301 2” Injection Tube 1/4 NPT Sch 160 x Open (316/L S.S. only)
630121 2” Injection Tube 1/4 NPT x Open (316/L S.S. only)
630123 2” Injection Tube 1/2 NPT x Open
630130 2” Injection Tube 3/4 NPT x Open (316 S.S. only)
Code Material*
S31600/S31603 316/L Stainless Steel
S31803 Duplex Stainless Steel
S32760 Super Duplex Stainless Steel
Code Order Length
LL.LL Length in 1/4” increments from 1.25 to 36.00 inches

6301 10.00 Example

630121 S31600 10.00 Example
*Consult Factory for materials not specified above.
 50 Flarweld Chemical Injection

4. & 5. Nipples & Shut-Off Valves

Short nipples and shut-off valves are available to interface the Tee Access Fitting Assembly with the Injection/Sampling System.

Nipple*
The nipple is typically a MNPT x MNPT connection between a side-tee access fitting and a shut-off valve.

Table 4 – Ordering Information – Nipple Size 1/4”, 1/2”, 3/4”

Part Number Description
128993 Nipple Size - 1/4” – Pipe Schedule 80
127472 Nipple Size - 1/2” – Pipe Schedule 80
000738 Nipple Size - 1/2” – Pipe Schedule 160
000857 Nipple Size - 1/2” – Pipe Schedule XXS
125504 Nipple Size - 3/4” – Pipe Schedule 160
000969 Nipple Size - 3/4” – Pipe Schedule XXS
Code Material** (Omit for 316/316L S.S.)
S31803 Duplex Stainless Steel
Code Order Length (omit for standard 4.00 inches)
5.00” 5 Inches
6.00” 6 Inches

128993 5.00” Example

*Nipples used in conjunction with a Double Block and Bleed Valve (DBBV) should be sized at a minimum length of 5.00” to allow adequate space for operation of both
valve handles.
**Consult Factory for materials not specified above.

Shut-Off Valve*
The shut-off valve is typically a FNPT x FNPT connection between a nipple and customer’s inlet/outlet connection.

Table 5 – Ordering Information – 1/4”, 1/2”, 3/4”, & 1” Shut-Off Valves

Part Number Size Material** Valve Type
200022 1/4” FNPT x 1/4” FNPT 316 SS Needle
200022-X9 1/4” FNPT x 1/4” FNPT 316 SS DBBV
200022-X6 1/4” FNPT x 1/4” FNPT Duplex SS Needle
200022-X7 1/4” FNPT x 1/4” FNPT Hastelloy C-276 Needle
200023 1/2” FNPT x 1/2” FNPT 316 SS Needle
200023-X11 1/2” FNPT x 1/2” FNPT 316 SS DBBV
200023-X24 1/2” FNPT x 1/2” FNPT 316L SS DBBV
200023-X2 1/2” FNPT x 1/2” FNPT Duplex SS Needle Needle Shut-Off Valve
200023-X21 1/2” FNPT x 1/2” FNPT Duplex SS DBBV

200023-X19 1/2” FNPT x 1/2” FNPT Monel Needle

200023-X13 1/2” FNPT x 1/2” FNPT Hastelloy C-276 Needle
200024 3/4” FNPT x 3/4” FNPT 316 SS Needle
200024-X9 3/4” FNPT x 3/4” FNPT 316L SS DBBV
200024-X8 3/4” FNPT x 3/4” FNPT Duplex SS Needle
200025 1” FNPT x 1” FNPT 316 SS Needle
200025-X3 1” FNPT x 1” FNPT 316L SS DBBV Double Block & Bleed
200025-X2 1” FNPT x 1” FNPT Duplex SS Needle Shut-Off Valve (DBBV)

* The following valve details are applicable unless stated otherwise: - Working Criteria: 6000psi @ 200°F (93°C), Seat / Seals: Teflon
**Consult Factory for materials not specified above.
 50 Flarweld Chemical Injection

Flow Rate Determination

For approximate flow rate determination with a differential pressure not stated above (and over 40 psi) use the following equation:
Q1
P1 = Pressure Differential from the table above
= Desired Flow Rate (Q 2) P2 = Desired Pressure Differential
P10.5 P 0.5 Q1 = Flow Rate from the table corresponding to P1
2 Q2 = Desired Flow Rate

Sizing Formulas
Center of the line
Our recommended injection location is the center of pipe. Thus the following sizing formula is applicable for Non-Flanged Access
Fitting Assemblies.

A + WG + 1/2 PD - 2.25 - N = Length* A = Access Fitting Assembly length

WG = Weld Gap (1/16”, or 1.59 mm is normal per ANSI B31.1. 1973)
PD = Pipe outside diameter
N = Injection/Sampling Nut length

Bottom of the line

Sampling locations may vary. If sampling from the center of pipe or vessel, the above listed sizing formula applies. If bottom of line
sampling is required with the access fitting assembly in the 12:00 O’clock position, the following sizing formula applies for Non-
Flanged Access Fitting Assemblies.

A + WG + PD - 2.50 - N - PW = Length* A = Access Fitting Assembly length

WG = Weld Gap (1/16”, or 1.59 mm is normal per ANSI B31.1. 1973)
PW = Pipe Wall thickness
PD = Pipe outside diameter
N = Injection/Sampling Nut length

*Ordering Lengths should be rounded down to nearest 1/4" increments.

Ordering Example
You want to inject into a 12” oil line and your injection line is 1/2” pipe. Your complete system would consist of the following:

Quantity Part Number Description

2" Flarweld Access Fitting Assembly, 6.25" height, 1/2" Tee
body in A105 Carbon Steel for 12" to 18" pipe sizes with
1 50-111-2-18-K03504-10 Solid Plug Assembly in 316 SS material with Teflon Primary
Packing, Viton O-ring, and a 6,000 psi rated heavy pressure-
retaining cover with bleed plug and pressure gauge.
Injection Nut Assembly 1/4 NPT x 2.75” Inj. Nut was chosen
1 204728
since the access fitting body height is 6.25”

2” Injection Tube 1/4” x Quill 7.75-316 (6.25 (A) + .0625

1 6300-7.75
(WG) + 6.375 (1/2PD -2.25 -2.75 (N) = 7.75)

1 127472 Nipple 1/2” x 4.00 - 316

1 200023 Shut-Off Valve 1/2” NPT - 316

 50 Flarweld Chemical Injection

Maintenance & Services

Service Kits
Cosasco highly recommends the solid carrier plug to be replaced after three insertions or if damaged. A primary packing should be
replaced after every service, and for a solid carrier plug, the secondary O’ ring seal; for an injection nut, the injection nut seals, if they
are excessively worn or damaged.
Injection Location
Replacement Part Included Stage 1 Stage 2
Solid Plug l
Primary Packing l l
Plug O-ring l l
PRC O-ring l l
Set Screw(s) l l
Injection Nut Seal Kit l l

Service Kit Ordering Information

Model
740138 Access Fitting Service Kit
Code Maintenance Level*
1 Stage 1
2 Stage 2
Code Type of Monitoring Location
INJ Chemical Injection
Code Plug Assembly – Enter code for plug type from options below
Type (1st Digit) Alloy Mat’l (2nd Digit) Packing Seal (3rd Digit)
0 Not Req. 0 Not Req. 0 Not Req.
1 Solid 1 316/316L S.S. 1 Viton O-Ring Teflon Primary Packing - ** -15 to 400° F (-26 to 204°C)
3 Hastelloy C-276 2 Ethylene Propylene O-Ring Vespel Primary Packing - * -70 to 250°F (-56 to 121°C)
4 Nitronic 60 3 Kalrez O-Ring Vespel Primary Packing - ** -15 to 450°F (-26 to 232°C)
5 Carbon Steel 4 No O-Ring Nitronic 60 Primary Packing - ** -50 to 450°F (-45 to 232°C)
6 Inconel 625 5 Hydrin O-Ring Teflon Primary Packing - ** -40 to 275°F (-40 to 135°C)
7 2205 Duplex S.S. 6 Nitrile O-Ring Teflon Primary Packing - ** -30 to 250°F (-35 to 121°C)
XXX
7 Ethylene Propylene O-Ring, Teflon Primary Packing - ** -70 to 250°F (-56 to
121°C)
8 EDR Viton O-Ring Teflon Primary Packing - ** -15 to 400° F (-26 to 204°C)
9 Kalrez O-Ring Teflon Primary Packing - ** -15 to 450° F (-26 to 232°C)
A HNBR EOL 101 O-Ring Teflon Primary Packing - ** -13 to 320° F (-25 to 160° C)
B HNBR EOL 985 O-Ring Teflon Primary Packing - ** -67 to 302° F (-55 to 150° C)
C AFLAS 69/90 O-Ring Teflon Primary Packing ** 32 to 392° F (0 to 200° C)
D Viton “B” (VB185-70) Teflon Primary Packing ** 15 to 400° F (-26 to 204°C)
Code Seal Material Option for Pressure Retaining Cover
1 Viton
2 Ethylene Propylene
3 Kalrez
5 Epchlorohydrin
6 Nitrile
8 EDR Viton
A HNBR EOL 101 O-Ring Teflon Primary Packing - * -13 to 320˚F (-25 to 160˚C)
B HNBR EOL 985 O-Ring Teflon Primary Packing - * -13 to 320˚F (-25 to 160˚C)
C AFLAS 36/90 O-Ring Teflon Primary Packing - * 32 to 392˚F (0 to 200˚C)

740138 1 INJ 111 1 Example

* Stage 1 Service Kit includes basic replacement parts and is recommended for every pull/change out. Stage 2 Service Kit is for a complete overhaul and
recommended for every 3rd pull/change out. Note, this is a minimum recommended maintenance requirement, Stage 2 may be required at more frequent
intervals based on exposure time and type of process media.
** Nominal Temperature Range
 50 Flarweld Chemical Injection

SAFR Services
The Cosasco SAFR (Surveyed Access Fitting Register) program is designed to assist in the short and
long term maintenance of access fittings. The program can be used solely to audit systems, or in
tandem with service campaigns such as coupon and data retrieval. With life extension of assets and
the general increase in number of monitoring systems, it’s increasingly important that systems are
surveyed to ensure that material selection is fit for purpose as well as the overall physical condition
of the fitting.

Non-OEM parts exist in facilities where third part or competing contractors carry out maintenance
and monitoring. This can lead to serious consequences as often times materials installed do not
match the material retrieved. Simple errors can lead to unmanaged risk. Correct device selection and
orientation is extremely important to achieving reliable data and ensuring plant integrity.
SAFR Tablet

Cosasco Care Service Plans & Extended Warranty

Cosasco Care Service Plans and Extended Warranty offer a broad spectrum of services to make sure your assets and plant operations
are running at their peak performance and under the safest conditions. Cosasco Care Extended Warranty comes as standard with
Cosasco Care Essential, Plus, and Premium Service Plans. All Service plans include access to the Cosasco SAFR (Surveyed Access
Fitting Register) maintenance program; offline installation, retrieval and maintenance of coupons and probes; coupon analysis and
reporting; technical support; Cosasco Data Offline software support; data management and reporting; and safety awareness training.
Contact our Cosasco Care team for more details and pricing.

Cosasco Care Services

Cosasco ©Rohrback Cosasco Systems, Inc. All rights reserved

11841 Smith Avenue The contents of this publication are presented for information purposes only, and while effort has been made to ensure their accuracy, they are not
Santa Fe Springs, CA 90670, USA to be construed as warranties or guarantees, express or implied, regarding the products or services described wherein or their use or applicability.
Tel: 1-562-949-0123 We reserve the right to modify or improve the designs or specifications of our products at any time without notice.
Email: sales@cosasco.com
Website: www.cosasco.com

50CI-DSrevA
Rev. Date 4/23/2018

www.cosasco.com