Welker AD905BP Installation, Operation And Maintenance Manual Download Page 11

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2.1 Before You Begin

After unpacking the unit, check the equipment for compliance and any damage that may have occurred during shipment.

Immediately contact a Welker representative if you received damaged equipment.

When sealing fittings with PTFE tape, refer to the proper sealing instructions for the brand used.

Take care not to close the pipeline isolation valve on the insertion shaft while the shaft is inserted in the pipeline. This is the most

common cause of damage to Welker probes.

Welker recommends that the unit be installed to the side of the pipe and inserted into the center one-third (¹⁄₃) of the

pipeline in a location where the product is well-mixed and will yield an accurate and representative sample.

Locate the unit at least two to four pipe diameters downstream of an inline static mixer or other flow conditioning

system.

Handle the unit with care. Avoid bending the insertion shaft, which has a polished surface that travels through seals.

Operate the unit slowly and smoothly while inserting and retracting to avoid damaging the unit.

SECTION 2: INSTALLATION & OPERATION

IOM-189

MODEL: INFLOW™ ACE MANUAL INSERTION

REV: G

13839 West Bellfort Street, Sugar Land, TX 77498

welker.com

Service Department 281.491.2331

Summary of Contents for AD905BP

Page 1: ...INSTALLATION OPERATION AND MAINTENANCE MANUAL WELKER INFLOW ACE CRUDE OIL SAMPLER MANUAL INSERTION DRAWING NUMBERS AD905BP AD905BU MANUAL NUMBER IOM 189 REVISION Rev G 11 11 2019 ...

Page 2: ...ant Information 5 1 4 Specifications 6 1 5 Equipment Diagrams 7 2 INSTALLATION OPERATION 11 2 1 Before You Begin 11 2 2 Setting the Sample Volume 12 2 3 Preparing the Unit for Installation 15 2 4 Installing the Unit 20 2 5 Operating the Unit 23 2 6 Purging the Unit 25 2 7 Emergency Shutoff 26 2 8 Retracting the Unit 27 3 MAINTENANCE 29 3 1 Before You Begin 29 3 2 Maintenance Optional Insertion Too...

Page 3: ...rect installation and operation however are the responsibility of the end user Welkerreserves the right to make changes to this manualand allproducts in order to improve performance and reliability BEFORE YOU BEGIN Read these instructions completely and carefully IMPORTANT Save these instructions forlocal inspector s use IMPORTANT Observe all governing codes and ordinances Note to Installer Leave ...

Page 4: ...able insertion length to accommodate different pipeline sizes Sampling may be hydraulically or pneumatically operated but is electronically controlled from a Programmable Logic Controller PLC or other signal control system Sampling may be timed or proportional to flow With protection from an external sand relief and check valves designed for sandy oils this sampler is capable of sampling product c...

Page 5: ...stalled 3 After Welker Great Barrier Sealant has been injected into the lubrication port the grease fitting must be removed and the plug reinstalled before the sampler can be exposed to pipeline pressure and returned to operation Failure to remove the grease fitting and return the plug to the lubrication port priorto exposing the samplerto pipeline pressure could result in a product leak and orinj...

Page 6: ... 300 ANSI Carbon Steel 740 psig 20 F to 100 F 51 barg 28 C to 37 C 600 ANSI Carbon Steel 1480 psig 20 F to 100 F 102 barg 28 C to 37 C Maximum Allowable Insertion Retraction Pressure Manual Insertion 40 psig 2 7 barg Pipeline Connection Size 2 Standard or 3 Rating 150 300 or 600 ANSI RF Sample Outlet Connection FNPT Motor Housing Actuation Ports FNPT FNPT FNPT Standard Insertion Length 0 24 0 60 c...

Page 7: ...1 5 Equipment Diagrams Figure 1 inFlow ACE Diagram 7 IOM 189 MODEL INFLOW ACE MANUAL INSERTION REV G 13839 West Bellfort Street Sugar Land TX 77498 welker com Service Department 281 491 2331 ...

Page 8: ...Figure 2 inFlow ACE Connections Diagram 8 IOM 189 MODEL INFLOW ACE MANUAL INSERTION REV G 13839 West Bellfort Street Sugar Land TX 77498 welker com Service Department 281 491 2331 ...

Page 9: ...Figure 3 inFlow ACE With Optional Insertion Tool Diagram 9 IOM 189 MODEL INFLOW ACE MANUAL INSERTION REV G 13839 West Bellfort Street Sugar Land TX 77498 welker com Service Department 281 491 2331 ...

Page 10: ...re 4 inFlow ACE With Optional Insertion Tool Connections Diagram 10 IOM 189 MODEL INFLOW ACE MANUAL INSERTION REV G 13839 West Bellfort Street Sugar Land TX 77498 welker com Service Department 281 491 2331 ...

Page 11: ...unit be installed to the side of the pipe and inserted into the center one third of the pipeline in a location where the product is well mixed and will yield an accurate and representative sample 2 Locate the unit at least two to four pipe diameters downstream of an inline static mixer or other flow conditioning system 3 Handle the unit with care Avoid bending the insertion shaft which has a polis...

Page 12: ...ction Head Diagram Figure 6 C Style Collection Head Diagram 2 Loosen the jam nut on the collection head Figure 5 or Figure 6 3 To decrease the sample volume screw the collection head assembly clockwise This shortens the stroke of the collection head piston 4 To increase the sample volume screw the collection head assembly counterclockwise This lengthens the stroke of the collection head piston One...

Page 13: ...olume Once the desired volume is set the sample volume can be changed at any time externally without removing the inFlow ACE from the pipeline Figure 7 Upper Housing Diagram 7 As necessary gently push down on the external adjustment body so that the external adjustment rings are accessible through the chamber Figure 8 13 IOM 189 MODEL INFLOW ACE MANUAL INSERTION REV G 13839 West Bellfort Street Su...

Page 14: ...he lower external adjustment ring until it meets the upper external adjustment ring Tighten firmly to prevent slippage that might lead to inconsistencies in the sample volume The lowerexternal adjustment ring and O ring are used to lock the upperexternal adjustment ring in place to prevent slippage and subsequent changes in the sample volume during sampling 11 Turn ON and actuate the hydraulic or ...

Page 15: ...ose end of the sample outlet flexline into the elbow above the sample outlet Figure 9 Aligning the Lock Collar 6 Determine the direction of product flow in the pipeline 7 Lay the inFlow ACE on a smooth clean surface 8 If the collection head is not fully visible gently pull the collection head out of the lubricator body Note that the lock collarmust be loose in orderto pull the collection head out ...

Page 16: ...indicatorrod will be an external reference point to the collection head opening Figure 10 Aligning the Collection Head 16 IOM 189 MODEL INFLOW ACE MANUAL INSERTION REV G 13839 West Bellfort Street Sugar Land TX 77498 welker com Service Department 281 491 2331 ...

Page 17: ... shaft insertion length Figure 11 Determining the Insertion Depth 13 Pull up on the insertion shaft to ensure that it is fully retracted The end of the collection head should be flush with or in close proximity to the flange face Figure 12 14 Beginning at the top edge of the lockdown studs measure along the insertion shaft to the desired insertion length Figure 12 As needed use a felt tip pen to m...

Page 18: ... the Insertion Length 15 Remove the hex nuts from the lockdown studs Figure 13 18 IOM 189 MODEL INFLOW ACE MANUAL INSERTION REV G 13839 West Bellfort Street Sugar Land TX 77498 welker com Service Department 281 491 2331 ...

Page 19: ...ith the opening in the collection head 19 Tighten the cap screws on the sides of the lock collar to secure the lock collar to the outer shaft at the marked point Figure 13 This procedure ensures that the insertion length will be mechanically limited by the lock collarand that the lock collarwill hold the probe in place when underpressure 19 IOM 189 MODEL INFLOW ACE MANUAL INSERTION REV G 13839 Wes...

Page 20: ...ue to step 3 If the unit will be inserted using the optional insertion tool proceed to step 7 Manual Insertion At pressures above 40psig the inFlow ACE cannot be safely inserted orretracted manually To insert the inFlow ACE the pipeline pressure will need to be reduced to 40psig orbelow At least two 2 people are required to correctly and safely insert the inFlow ACE into the pipeline 3 Slowly open...

Page 21: ...dicator rod should be parallel to the pipeline 14 Continue to stroke the customer hydraulic hand pump until either the desired insertion depth has been reached or the insertion tool shafts are completely inserted into the insertion tool housings 15 As necessary align the lock collar holes with the lockdown studs on the lubricator body 16 Once the lock collar seats on the lockdown studs return the ...

Page 22: ...rstandard applications and a minimum of tubing forhigh speed applic ations The normally open port should be stamped A or NO The normally closed port should be stamped B or NC 22 Open emergency shutoff valve E Figure 1 or Figure 3 23 As necessary adjust the external sand relief With emergency shutoff valve E open tighten the jam nut on the external sand relief until no product emerges from the outl...

Page 23: ...imer or controller to actuate the solenoid at the desired sampling actuation frequency based on the sampling equations provided Figure 14 Figure 14 Sampling Frequency Equations Neverfill the containerabove 80 of its capacity Allow at least 20 room forproduct expansion should the containerbe exposed to increased temperatures Note the 0 8in Equation 1represents the 80 volume limit forliquid sampling...

Page 24: ...ion shaft with product before sample appears at the outlet port 6 Collect a sample from the sample outlet to ensure that the sample volume collected is the same as the desired sample volume Welkerrecommends the WelkerCheckpoint Sample Bite Verification Panel foruse with this unit 24 IOM 189 MODEL INFLOW ACE MANUAL INSERTION REV G 13839 West Bellfort Street Sugar Land TX 77498 welker com Service De...

Page 25: ...ure that the purge pressure i e the purge setting minus the external adjustable relief setting does not exceed the pressure rating of the sample container 3 Turn ON the inert gas supply 4 Open purge valve P Figure 1 or Figure 3 5 Allow product in the inFlow ACE to drain Monitor the sample container for under or over purging If no inert gas is heard entering the sample container the purge pressure ...

Page 26: ...d may damage the pump Free flow from the sample outlet indicates that the external adjustable relief has not been set correctly orthat the external adjustable relief has failed 2 If leaking becomes evident elsewhere on the inFlow ACE turn OFF the hydraulic or pneumatic supply to the motor and then tighten the packing adjustment nut to stop the leak until the unit can be removed for service 26 IOM ...

Page 27: ...quired to correctly and safely retract the inFlow ACE from the pipeline 6 With one person firmly pushing on the top of the motor housing of the inFlow ACE another person can remove the hex nuts securing the lock collar to the lockdown studs on the lubricator body Figure 13 Failure to ensure that adequate pressure is applied to the top of the unit at the motorhousing priorto retraction could result...

Page 28: ...necting the customer hydraulic hand pump to retraction valve B and applying hydraulic pressure to the insertion tool housings Once the insertion shaft begins to retract do not open the valve any further The insertion shaft should be retracted slowly and smoothly Opening the valve too quickly ortoo much may cause the insertion shaft to retract from the pipeline too quickly and may result in damage ...

Page 29: ...esults Forsample exposed seals Welkerrecommends non hydrocarbon based lubricants such as Krytox Fornon sample exposed seals Welkerrecommends eithernon hydrocarbon based lubricants orsilicone based lubricants such as Molykote 111 Afterthe seals are installed the outerdiameterof shafts and innerdiameterof cylinders may be lubricated to allow smooth transition of parts 3 All maintenance and cleaning ...

Page 30: ...sertion Tool Diagram 3 Remove the hex nuts flat washers and lock washers from the top of each insertion tool shaft and upper bracket standoff 4 Remove the top brackets 5 Unscrew the fastener screws from the upper bracket plate and then loosen the front fastener screw on the upper bracket 6 Holding the upper bracket standoffs carefully lift the stabilizer bar and upper bracket from the motor housin...

Page 31: ...rtion tool shaft piston for signs of damage or wear Replace as necessary 16 Inspect the insertion tool housing for scratches All cylinder bores should be clean If scratches are present polish the insertion tool housing 17 Inspect the insertion tool shaft for scratches If scratches are present polish the insertion tool shaft 18 Wrap the exposed threads at the top of the insertion tool shaft with PT...

Page 32: ...insertion shaft and removing the unit from the pipeline 2 If applicable remove the optional insertion tool prior to performing maintenance See Section 3 2 Maintenance Optional Insertion Tool for instructions on removing and maintaining the insertion tool 3 Relieve any trapped pressure by loosening the jam nut and turning the adjusting screw on the external sand relief counterclockwise and opening ...

Page 33: ...bend or otherwise damage the purge tube 11 Unscrew the external sand relief from emergency shutoff valve E 12 Unscrew the flexline from the elbow in the external sand relief 13 Unscrew the base of the external sand relief from the body Figure 19 Figure 19 External Sand Relief Maintenance Diagram 14 Replace the O ring on the base 15 Unscrew the jam nut from the adjusting screw 16 Inspect the poppet...

Page 34: ...rew the motor top from the motor housing 24 Carefully remove the motor top from the external adjustment body 25 Carefully unscrew the external adjustment body from the insertion shaft Note that the external adjustment rings will remain attached to the external adjustment body and will also be removed at this time 26 Unscrew the cap screws from the top cap and carefully remove the top cap from the ...

Page 35: ... 31 Replace the O rings and back ups on the top cap 32 Inspect the wiper ring and shaft bearing in the top cap Replace them if they show signs of wear or damage 33 Replace the O ring and crown seal on the piston 34 Replace the O ring and back ups in the motor housing 35 Inspect the wiper ring and bearing in the motor housing Replace them if they shows signs of wear or damage 36 Inspect the polishe...

Page 36: ...acking gland body 40 Inspect the wiper ring in the packing adjustment nut Replace it if it shows signs of wear or damage 41 Replace the V ring packing in the packing gland body The V ring packing should be installed so that the V is open to the product pressure 42 Remove the cartridge seal body assembly from the packing gland body 43 Install a replacement cartridge seal body assembly to the packin...

Page 37: ...cap down to the motor housing 51 If the inFlow ACE is not equipped with the optional external adjustment continue to step 52 If the inFlow ACE is equipped with the optional external adjustment proceed to step 54 Without Optional External Adjustment Assembly 52 Following a cross bolting sequence install the bolts to the top cap and secure the top cap to the motor housing Figure 24 53 Proceed to ste...

Page 38: ...eal and then return the retaining ring to the end of the outer shaft 64 Remove the lubricator bushing U cup and back up from the bottom of the lubricator body 65 Install a replacement back up to the lubricator body 66 Inspect the U cup for damage or wear Replace as necessary 67 Install the U cup to the lubricator body The U cup should be installed so that the U is open to the product pressure 68 I...

Page 39: ...tall a replacement Welker Seal to the end of the outer shaft Figure 25 87 Using the retaining ring secure the Welker Seal in the outer shaft Figure 25 88 Tighten the collection head onto the outer shaft 89 If the inFlow ACE is not equipped with the optional insertion tool the unit is now ready for installation If the inFlow ACE is equipped with the optional insertion tool continue to step 90 for i...

Page 40: ... is operating improperly refer to the Installation Operation and Maintenance IOM Manual for the solenoid The sample container is not filling The inlet valve on the sample container may be closed The outlet on the sample container may be open The inFlow ACE is not collecting the correct sample volume The inFlow ACE may be set at a slower sampling frequency than desired The relief on the inFlow ACE ...

Page 41: ...he inFlow ACE may be set at a faster sampling frequency than desired The relief on the inFlow ACE may be set too low Welker recommends the Welker Checkpoint Sample Bite Verification Panel for verifying the sample volume of the inFlow ACE See Section 2 2 Setting the Sample Volume for instructions on adjusting the sample volume Adjust the inFlow ACE to sample at the desired rate Ensure that the calc...

Page 42: ...lker TCC 10 Transportable Crude Oil Container Other Installation Operation and Maintenance IOM Manuals suggested for use with this unit l Parker Hannifin Corporation Fluoropolymer Hose Welker IOM V174 Welker drawings and schematics suggested for use with this unit l Assembly Drawing AD905BP Standard inFlow ACE Manual Insertion l Assembly Drawing AD905BU inFlow ACE With Optional External Adjustment...

Page 43: ...pring of the internal sand relief for damage or wear Replace as necessary 6 Examine the poppet of the internal sand relief for damage or wear Replace as necessary Piston and Cylinder 7 Inspect the bushing for signs of wear Replace as necessary 8 Replace the O ring back up and PolyPak on the piston 9 Inspect the plated cylinder for scratches or other damage Polish or replace as necessary 10 Unscrew...

Page 44: ... the collection head aside and continue to the next step in Section 3 3 Maintenance inFlow ACE If maintenance is only being performed on the collection head screw the piston into the insertion shaft and then screw the collection head onto the outer shaft Tighten the jam nut to lock the collection head in place For maximum sample volume ensure that the bottom of the jam nut is flush with the bottom...

Page 45: ...at of the internal sand relief 5 Examine the spring of the internal sand relief for damage or wear Replace as necessary 6 Examine the poppet of the internal sand relief for damage or wear Replace as necessary Piston and Cylinder 7 Inspect the bearing and retaining ring for signs of wear Replace as necessary 8 Replace the O ring back ups and PolyPak on the piston 9 Inspect the plated cylinder for s...

Page 46: ...rming full maintenance on the inFlow ACE set the collection head aside and continue to the next step in Section 3 3 Maintenance inFlow ACE If maintenance is only being performed on the collection head screw the collection head onto the adapter and tighten the jam nut to lock the collection head in place For maximum sample volume ensure that the bottom of the adapter is flush with the bottom of the...

Page 47: ..._______________________________________ ____________________________________________________________________________________________________ ____________________________________________________________________________________________________ ____________________________________________________________________________________________________ _________________________________________________________...

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