Welker INFLOW Bedienungsanleitung

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

TABLEOFCONTENTS

2IOM-161 MODEL: INFLOW™ ACE WITHAICONTROL™ REV: D 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331

 SAFETY 3

1. PRODUCT INFORMATION 4

1.1 Introduction 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 Begin 26

3.2 Maintenance 27

3.3 Troubleshooting 36

  

 APPENDICES 38

 A: Referenced or Attached Documents 38

 B: D-Style Collection Head Maintenance 39



IMPORTANTSAFETYINFORMATION

READALLINSTRUCTIONS

Notes emphasize information and/or provide additional information to assist the user.

Caution messages appear before procedures that could result in damage to equipment if not observed.

Warning messages appear before procedures that could result in personal injury if not observed.

This manual is intended to be used as a basic installation and operation guide for the Welker inFlow™ ACE Crude Oil Sampler. For comprehensive instructions,

please refer to the IOM Manuals for each individual component. A list of relevant component IOM Manuals is provided in Appendix A of this manual.

The information in this manual has been carefully checked for accuracy and is intended to be used as a guide for the installation, operation, and maintenance of

the Welker equipment described in this manual. Correct installation and operation, however, are the responsibility of the end user. Welker reserves the right to make

changes to this manual and all products in order to improve performance and reliability.

BEFOREYOUBEGIN

Read these instructions completely and carefully.

IMPORTANT- Save these instructions for local inspector's use.

IMPORTANT- Observe all governing codes and ordinances.

Note to Installer - Leave these instructions with the end user.

Note to End User - Keep these instructions for future reference.

Installation of this inFlow™ ACE Crude Oil Sampler is of a mechanical nature.

Proper installation is the responsibility of the installer. Product failure due to improper installation is not covered under the warranty.

If you received a damaged inFlow™ ACE Crude Oil Sampler, please contact a Welker representative immediately.

Phone: 281.491.2331

Address: 13839 West Bellfort Street

Sugar Land, TX 77498

SAFETY

3IOM-161 MODEL: INFLOW™ ACE WITHAICONTROL™ REV: D 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331

1.1 Introduction

We appreciate your business and your choice of Welker products. The installation, operation, and maintenance liability for this

equipment becomes that of the purchaser at the time of receipt. Reading the applicable Installation, Operation, and

Maintenance (IOM) Manuals prior to installation and operation of this equipment is required for a full understanding of its

application and performance prior to use.*

If you have any questions, please call Welker at 1-281-491-2331.

*The following procedures have been written for use with standard Welker parts and equipment. Assemblies that have been modified may have additional

requirements and specifications that are not listed in this manual.

1.2 Product Description

The Welker inFlow™ ACE Crude OilSampler is an isokinetic probe sampler designed to extract a representative sample of liquid

product from the flowing stream. When used with a pipeline isolation valve, the inFlow™ ACE with AI Control™ can be safely

inserted and retracted without interfering with or venting pipeline pressure. Once all desired samples have been collected, the

inFlow™ ACE can be fully evacuated of internal sample volume using the purge tube, thus preparing the sampler for the next

sample batch.

The operator controls 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 proportional to flow.

With protection from an external sand relief and check valves designed for sandy oils, this sampler is capable of sampling

product containing sand or debris. For added safety, the inFlow™ ACE is equipped with a dustcover, shaft wipers to protect seals,

and an adjustable V-ring packing for emergency shutdown leak protection.

Designed with ease of use in mind, the external sample volume adjustment simplifies operation of the inFlow™ ACE even further.

The external adjustment allows the operator to adjust the sample volume without having to remove the inFlow™ ACE from the

pipeline.



For this manual, the term "PLC," or Programmable Logic Controller, will be used to refer to the PLC, DCS, or other signal control

system used by the customer to activate and operate the solenoid.

Welker may custom design the inFlow™ ACE to suit the particular application and specifications of each customer.

SECTION 1: PRODUCTINFORMATION

4IOM-161 MODEL: INFLOW™ ACE WITHAICONTROL™ REV: D 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331

1.3 Important Information

1. The lubrication port should remained plugged at all times except when performing maintenance on a sampler that has

been isolated from pipeline pressure and/or removed from the pipeline.

2. Prior to injecting Welker Great Barrier Sealant™ into the lubrication port, the plug must be removed and an

appropriately sized grease fitting installed.

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 prior to exposing the sampler to pipeline

pressure could result in a product leak and/or injury to the operator.

1.4 Specifications



The specifications listed in this section are generalized for this equipment. Welker can modify the equipment according to your

company's needs. Please note that the specifications may vary depending 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 Pressure

150 ANSI Carbon Steel: 285 psig @ -20 °F to 100 °F (19 barg @ -28 °C to 37 °C)

600 ANSI Carbon Steel: 1480 psig @ -20 °F to 100 °F (102 barg @ -28 °C to 37 °C)

Pipeline Connection Size: 2"

Rating: 150 or 600 ANSIRF

Sample Outlet Connection ¼" FNPT

Motor Housing Actuation Ports

¼" FNPT

½" FNPT

³⁄₈" FNPT (Standard)

Insertion Length

0–18" (0–45 cm)

0–24" (0–60 cm)

0–36" (0–91 cm)

Utility Requirements Hydraulic or Pneumatic Supply for Motor Operation: 120 psig (8 barg)

Inert Gas Supply for Purge Operation: ¼" FNPT Connection

Sample Volume D-Style Collection Head: 0.5–10 cc

Features

External Adjustment

External Sand Relief

Purge Tube

V-ring Packing

Options Pre-Set Collection Head

NACECompliance

5IOM-161 MODEL: INFLOW™ ACE WITHAICONTROL™ REV: D 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331

1.5 Equipment Diagrams

Figure 1: inFlow™ ACE Diagram

6IOM-161 MODEL: INFLOW™ ACE WITHAICONTROL™ REV: D 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331

Figure 2: inFlow™ ACE Connections Diagram

7IOM-161 MODEL: INFLOW™ ACE WITHAICONTROL™ REV: D 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331

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.



1. 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.

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 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 pull the collection head out of the lubricator body.



Note that the lock collar must be loose in order to pull the collection head out of the lubricator body.



4. Ensure that the lock collar is aligned with the alignment nuts (Figure 3). As necessary, loosen the cap screws on the sides

of the lock collar and rotate the lock collar until it is aligned with the alignment nuts.



Once the unit is installed to the pipeline, the alignment indicator rod will be an external reference point to the collection head

opening.



SECTION 2: INSTALLATION&OPERATION

8IOM-161 MODEL: INFLOW™ ACE WITHAICONTROL™ REV: D 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331

Figure 3: Lock Collar Diagram



5. Loosen the jam nut, and then turn the hanger until the opening in the collection head is aligned with the alignment

indicator rod on the lock collar (Figure 4). The opening in the collection 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.

9IOM-161 MODEL: INFLOW™ ACE WITHAICONTROL™ REV: D 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331

Setting the Insertion Length

7. Prior to installing the inFlow™ ACE, the length the insertion shaft will need to travel inside the pipeline must be

determined. Measure the distance the insertion shaft must travel from the top of the pipeline isolation valve to the

desired insertion depth (e.g., the center one-third (¹⁄₃) of the pipeline) (Figure 5). This will be the shaft insertion length.



Figure 5: Determining the InsertionDepth



8. 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 6).

9. Beginning at the top edge of the alignment nuts, measure along the insertion shaft to the desired insertion 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 still aligned with the opening in the collection head.

14. 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 3).



This procedure ensures that the insertion length will be mechanically limited by the lock collar and that the lock collar will

hold the probe in place when under pressure.

10 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

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