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3.1 Before You Begin

Welker recommends that the unit have standard yearly maintenance under normal operating conditions.

In cases of severe service, dirty conditions, excessive usage, or other unique applications that may lead to excess wear

on the unit, a more frequent maintenance schedule may be appropriate.

Prior to maintenance or disassembly of the unit, it is advisable to have a repair kit available for repairs of the system in

case of unexpected wear or faulty seals.

New seals supplied in spare parts kits should be lightly lubricated before being installed to ease the installation of the seals and

reduce the risk of damage when positioning them on parts. Wipe excess lubricant from the seals, as it may adversely affect

analytical instrument results.

For sample-exposed seals, Welker recommends non-hydrocarbon-based lubricants, such as Krytox®.

For non-sample-exposed seals, Welker recommends either non-hydrocarbon-based lubricants or silicone-based lubricants, such

as Molykote® 111.

After the seals are installed, the outer diameter of shafts and inner diameter of cylinders may be lubricated to allow smooth

transition of parts.

All maintenance and cleaning of the unit should be performed on a smooth, clean surface.

Welker recommends having the following tools available for maintenance. Please note that the exact tools required may

vary by model.

Adjustable Wrench (Qty. 2)

Crimp

Hex Key Set

High Pressure Grease Gun

Needle Nose Pliers

Reversible Snap Ring Pliers

Seal Pick

Tongue and Groove Pliers

Welker Great Barrier Sealant™

SECTION 3: MAINTENANCE

IOM-161

MODEL: INFLOW™ ACE WITH AI CONTROL™

REV: D

13839 West Bellfort Street, Sugar Land, TX 77498

welker.com

Service Department 281.491.2331

Содержание INFLOW

Страница 1: ...INSTALLATION OPERATION AND MAINTENANCE MANUAL WELKER INFLOW ACE CRUDE OIL SAMPLER WITH AI CONTROL DRAWING NUMBER AD885BA MANUAL NUMBER IOM 161 REVISION Rev D 12 3 2019 ...

Страница 2: ...roduction 4 1 2 Product Description 4 1 3 Important Information 5 1 4 Specifications 5 1 5 Equipment Diagrams 6 2 INSTALLATION OPERATION 8 2 1 Before You Begin 8 2 2 Preparing the Unit for Installation 8 2 3 Installing the Unit 11 2 4 Setting the Sample Volume 16 2 5 Operating the Unit 19 2 6 Purging the Unit 20 2 7 Emergency Shutoff 21 2 8 Retracting the Unit 22 3 MAINTENANCE 26 3 1 Before You Be...

Страница 3: ...rrect 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...

Страница 4: ... the insertion and retraction of the probe by manipulating valves and applying process or auxiliary pressure The inFlow ACE features an adjustable 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 proportion...

Страница 5: ...ending on the customization of your equipment Table 1 inFlow ACE Specifications Products Sampled Condensate Crude Oil Liquid Products Compatible With the Materials of Construction Refined Hydrocarbons and Water Materials of Construction 316 316L Stainless Steel Wetted Parts Carbon Steel Lubricator Body PTFE Kalrez Wetted Seals and Viton Non Wetted Seals Others Available Maximum Allowable Operating...

Страница 6: ...1 5 Equipment Diagrams Figure 1 inFlow ACE Diagram 6 IOM 161 MODEL INFLOW ACE WITH AI CONTROL REV D 13839 West Bellfort Street Sugar Land TX 77498 welker com Service Department 281 491 2331 ...

Страница 7: ...Figure 2 inFlow ACE Connections Diagram 7 IOM 161 MODEL INFLOW ACE WITH AI CONTROL REV D 13839 West Bellfort Street Sugar Land TX 77498 welker com Service Department 281 491 2331 ...

Страница 8: ...g the insertion shaft which has a polished surface that travels through seals 4 Operate the unit slowly and smoothly while inserting and retracting to avoid damaging the unit 2 2 Preparing the Unit for Installation Aligning the Lock Collar 1 Determine the direction of product flow in the pipeline 2 Lay the inFlow ACE on a smooth clean surface 3 If the collection head is not fully visible gently pu...

Страница 9: ...ion head should face the direction of product flow so that the flowing stream will pass through the opening Figure 4 D Style Collection Head Diagram 6 Tighten the jam nut on the collection head The tightened jam nut and safety wire will prevent the collection head from turning 9 IOM 161 MODEL INFLOW ACE WITH AI CONTROL REV D 13839 West Bellfort Street Sugar Land TX 77498 welker com Service Departm...

Страница 10: ...ertion length Figure 6 As needed use a felt tip pen to mark this point Figure 6 Setting the Insertion Length 10 Remove the hex bolts from the alignment nuts Figure 3 11 Loosen the cap screws on the sides of the lock collar Figure 3 12 Carefully slide the lock collar up the shaft to the shaft insertion length taking care not to scratch the outer shaft 13 Ensure that the alignment indicator rod is s...

Страница 11: ... should NOT contact the probe shaft as scratching orotherdamage to the shaft may lead to loss of integrity of the sealing surface The vent drain outlet on the lubricatorbody must be pointed down If the unit will be inserted using hydraulic fluid continue to step 3 If the unit will be inserted using an auxiliary gas proceed to step 13 If the unit will be inserted using pipeline product proceed to s...

Страница 12: ...r The insertion shaft should be inserted slowly and smoothly Opening the valve too quickly ortoo much may cause the insertion shaft to insert into the pipeline too quickly and may result in damage to the unit 7 Using the alignment indicator rod guide the shaft slowly into the pipeline The alignment indicator rod should be parallel to the pipeline 8 As necessary align the lock collar holes with the...

Страница 13: ... slowly and smoothly Opening the valve too quickly ortoo much may cause the insertion shaft to insert into the pipeline too quickly and may result in damage to the unit 18 Using the alignment indicator rod guide the shaft slowly into the pipeline The alignment indicator rod should be parallel to the pipeline 19 As necessary align the lock collar holes with the alignment nuts on the top cap Figure ...

Страница 14: ...peline The alignment indicator rod should be parallel to the pipeline 28 As necessary align the lock collar holes with the alignment nuts on the top cap Figure 3 29 Once the lock collar seats on the alignment nuts return the hex bolts to the alignment nuts and tighten firmly Figure 3 DO NOT stop applying pressure to the insertion shaft until the lock collarhas been secured to the alignment nuts 30...

Страница 15: ...lly open port should be stamped A or NO The normally closed port should be stamped B or NC 36 Open emergency shutoff valve E Figure 1 37 As necessary adjust the external sand relief With emergency shutoff valve E open loosen the jam nut tighten the adjusting screw on the external sand relief and then tighten the jam nut as a locking device Figure 13 Afterthe external sand relief valve has been set...

Страница 16: ... the desired sample volume and installing the adjustment pin to the predetermined slot The sample volume is determined by the distance between the upperexternal adjustment ring and the adjustment pin 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 2 Determine to which slot the ad...

Страница 17: ...ttom of the external adjustment chamber and the upper external adjustment ring tightened down on top of it Figure 9 Figure 9 Setting the External Adjustment Rings 17 IOM 161 MODEL INFLOW ACE WITH AI CONTROL REV D 13839 West Bellfort Street Sugar Land TX 77498 welker com Service Department 281 491 2331 ...

Страница 18: ...consistencies in 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 6 Slide the dustcover up to cover the external adjustment chamber Figure 7 7 Install the adjustment pin through the dustcover to the appropriate slot 8 Turn ON and actuate the hydrauli...

Страница 19: ...uld the containerbe exposed to increased temperatures Note the 0 8in Equation 1represents the 80 volume limit forliquid sampling 4 Ensure that emergency shutoff valve E is open Figure 1 5 As necessary turn on electrical power and activate the hydraulic or pneumatic supply to actuate the solenoid at the set sampling frequency At start up several actuations may be required to displace trapped airand...

Страница 20: ...ert gas supply pressure to approximately 50 psig above the external relief on the inFlow ACE Priorto purging the unit ensure 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 5 Allow product in the inFlow ACE to drain Monitor the sample c...

Страница 21: ...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 21 IOM ...

Страница 22: ... and disconnect the hydraulic or pneumatic supply lines 4 Close emergency shutoff valve E Figure 1 5 Disconnect the sample container from the sample outlet If the unit will be retracted using hydraulic fluid continue to step 6 If the unit will be retracted using an auxiliary gas proceed to step 14 If the unit will be retracted using pipeline product proceed to step 24 22 IOM 161 MODEL INFLOW ACE W...

Страница 23: ...top of the lock collar Figure 3 10 Slowly drain the hydraulic fluid from the insertion cylinder This will relieve pressure from the internal shaft piston allowing the insertion shaft to begin retracting from the pipeline If pipeline pressure is not sufficient to push the insertion shaft out of the line the insertion shaft may be retracted manually or by applying auxiliary gas to the vent outlet On...

Страница 24: ... top of the lock collar Figure 3 21 Slowly open vent relief valve B This will relieve pressure from the internal shaft piston allowing the insertion shaft to begin retracting from the pipeline If pipeline pressure is not sufficient to push the insertion shaft out of the line the insertion shaft may be retracted manually or by applying auxiliary gas to the vent outlet Once the insertion shaft begin...

Страница 25: ...ertion shaft to retract from the pipeline too quickly and may result in damage to the unit 29 Once the insertion shaft is fully retracted close vent relief valve B and then close the pipeline isolation valve to isolate the unit from pressure Figure 1 30 Continue to step 31 to complete retraction Completing Retraction 31 Loosen the cap screws on the sides of the lock collar and then slide the lock ...

Страница 26: ... results 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 cleanin...

Страница 27: ...ock collar and then expose the collection head manually by gently pushing the collection head out of the lubricator body 5 As necessary cut the safety wire from the relief cap to the jam nut and then remove the safety wire 6 Unscrew and remove the collection head assembly from the outer shaft 7 Refer to Appendix B D Style Collection Head Maintenance for instructions on performing maintenance on th...

Страница 28: ...d Relief Maintenance Diagram 13 Replace the O ring on the base 14 Unscrew the jam nut from the adjusting screw 15 Inspect the poppet for scratches or other damage If scratches or other damage are present on the poppet face seat replace the poppet 16 Reassemble the external sand relief 17 Screw the external sand relief into emergency shutoff valve E Figure 12 18 Screw the flexline into the elbow in...

Страница 29: ...ove the packing gland body from the insertion shaft Take care not to scratch or otherwise damage the insertion shaft assembly 23 Remove the dustcover from the packing gland body 24 Loosen the setscrews in the upper and lower lock collars on the external adjustment body and then remove the lock collars from the insertion shaft assembly Figure 14 Take care not to misplace the pins that align the loc...

Страница 30: ...k on the top cap 28 Inspect the wiper ring in the top cap Replace it if it shows signs of wear or damage 29 Replace the O ring and crown seal on the piston 30 Replace the O ring and PolyPak on the motor housing 31 Inspect the wiper ring in the motor housing Replace it if it shows signs of wear or damage 32 Inspect the polished portion of the insertion shaft If any scratches or damage are present r...

Страница 31: ...nscrew the packing adjustment nut from the packing gland body 36 Inspect the wiper ring in the packing adjustment nut Replace it if it shows signs of wear or damage 37 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 38 Remove the cartridge seal body from the packing gland body 39 Install a replacement cartrid...

Страница 32: ...bove the external adjustment body and align the pin hole in the lock collar with the pin in the external adjustment body 45 Tighten the setscrews in the upper and lower lock collars to secure the adjustment assembly to the insertion shaft 46 Carefully insert the insertion shaft assembly through the packing gland body taking care not to scratch the shaft 47 Slide the gland cover onto the packing gl...

Страница 33: ...e the heavy hex nuts and alignments nuts and then slide the top cap off the outer shaft 56 Inspect the retaining ring bearing and wiper ring in the top cap Replace them if they show signs of wear or damage 57 Replace the O rings and back ups in the top cap 58 Remove the outer shaft from the insertion cylinder 59 Inspect the wiper ring and shaft bearing in the outer shaft Replace them if they show ...

Страница 34: ...age are present repair or replace as necessary 63 Closely inspect the polished outer diameter of the outer shaft Scratches or pits may cause the seals to leak If scratches or pits are present the unit may need to be repaired or replaced Contact Welker for service options 64 Inspect the shaft bearing in the outer shaft Replace it if it shows signs of wear or damage 65 Replace the U cup in the outer...

Страница 35: ...he tie bolts so that the lock collar can later be secured to the top cap Figure 20 Location of the four 4 alignment nuts is critical Figure 20 Correct Alignment Nut Installation 75 Following a cross bolting sequence tighten the alignment nuts and heavy hex nuts to the appropriate torque Figure 19 Figure 20 and Table 2 Table 2 Torque Specifications for Tie Bolts Tie Bolt Diameter Foot Pounds ft lb ...

Страница 36: ...ration and Maintenance IOM Manual for the EHUC Inspect the pneumatic supply and regulator to ensure that air is supplied at the appropriate pressure Use the manual override button on the solenoid and ensure proper operation If the solenoid 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 t...

Страница 37: ...e 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 4 Setting the Sample Volume for instructions on adjusting the sample volume Adjust the inFlow ACE to sample at the desired rate Ensure that the calcu...

Страница 38: ...Container l IOM 208 Welker 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 l Swagelok Company Proportional Relief Valves R Series Welker IOM V086 Welker drawings and schematics suggested for use with this unit l Assembly Drawing AD885BA Standard inFlow...

Страница 39: ...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 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 Unscre...

Страница 40: ...CE set the collection head aside and continue to the next step in Section 3 2 Maintenance If maintenance is only being performed on the collection head screw the piston onto 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 of t...

Страница 41: ..._______________________________________ ____________________________________________________________________________________________________ ____________________________________________________________________________________________________ ____________________________________________________________________________________________________ _________________________________________________________...

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