Welker INLOOP ACE User manual

INSTALLATION, OPERATION, ANDMAINTENANCEMANUAL
WELKER INLOOP™ ACE CRUDEOILSAMPLER
DRAWING NUMBER
AD905BL

MANUAL NUMBER
IOM-195

REVISION
Rev. B, 10/10/2019

TABLEOFCONTENTS
2IOM-195 MODEL: INLOOP™ ACE REV: B 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331
Copyright © 2019 Welker, Inc. All rights reserved. Welker®, W Welker®, W logo, WelkerScope®, Welker Jet®, and OdorEyes® are registered trademarks of Welker, Inc.
 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 Setting the Sample Volume 8
2.3 Preparing the Unit for Installation 10
2.4 Installing the Unit 10
2.5 Operating the Unit 12
2.6 Purging the Unit 13
2.7 Emergency Shutoff 14
  
3. MAINTENANCE 15
3.1 Before You Begin 15
3.2 Maintenance 16
3.3 Troubleshooting 22
  
 APPENDICES 24
 A: Referenced or Attached Documents 24
 B: D-Style Collection Head Maintenance 25


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 inLoop™ 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 inLoop™ 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 inLoop™ 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-195 MODEL: INLOOP™ ACE REV: B 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 inLoop™ ACE Crude OilSampler is an isokinetic probe sampler designed to extract a representative sample of liquid
product from the flowing stream. Once all desired samples have been collected, the inLoop™ ACE can be fully evacuated of
internal sample volume using the purge tube, thus preparing the sampler for the next sample batch.
The inLoop™ ACE was specifically designed to be installed as part of a fast loop, which will provide the sampler with a
continuous supply of product. 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 and relief valves designed for sandy oils, this sampler is capable of
sampling product containing sand or debris. For added safety, the inLoop™ 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 inLoop™ ACE even
further. The external adjustment allows the operator to adjust the sample volume without having to remove the inLoop™ ACE
from the fast loop.

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 inLoop™ ACE to suit the particular application and specifications of each customer.
SECTION 1: PRODUCTINFORMATION
4IOM-195 MODEL: INLOOP™ ACE REV: B 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: inLoop™ 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, Aluminum Non-Wetted Parts, PTFE, Kalrez®
Wetted Seals, and Viton® Non-Wetted Seals
Others Available
Maximum Allowable
Operating Pressure 1440 psig @ -20 °F to 100 °F (99 barg @ -28 °C to 37 °C)
Fast Loop Connection 1" – 600 ANSIRF
Sample Outlet Connection ¼" FNPT
Utility Requirements Hydraulic or Pneumatic Supply for Motor Operation: 100–150 psig (6–10 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
5IOM-195 MODEL: INLOOP™ ACE REV: B 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331

1.5 Equipment Diagrams
Figure 1: inLoop™ ACE Diagram
6IOM-195 MODEL: INLOOP™ ACE REV: B 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331

Figure 2: inLoop™ ACE Connections Diagram
7IOM-195 MODEL: INLOOP™ ACE REV: B 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.
2.2 Setting the SampleVolume
1. Locate the exposed external adjustment chamber in the motor top (Figure 3).

Setting the sample volume is accomplished by rotating the upper external adjustment ring to attain the desired sample
volume.

Once the desired volume is set, the sample volume can be changed at any time externally without removing the inLoop™ ACE
from the fast loop.

Figure 3: Upper Housing Diagram

SECTION 2: INSTALLATION&OPERATION
8IOM-195 MODEL: INLOOP™ ACE REV: B 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331

2. As necessary, gently push down on the external adjustment body so that the external adjustment rings are accessible
through the chamber (Figure 4).

Figure 4: Setting the External Adjustment Rings

3. Begin with the upper external adjustment ring at the top of the external adjustment body (Figure 4).

Welker recommends using a felt tip pen to mark the front of both external adjustment rings so that it is clear when the
adjustment rings have made a full rotation.

4. Using the provided external adjustment tool, turn the upper adjustment ring to the desired volume (Figure 4).

One full rotation of the upper external adjustment ring is approximately 1 cc if the inLoop™ ACE is equipped with the D-Style
collection head. Each hole in the upper external adjustment ring is equal to approximately 0.10 cc.

5. Turn the lower external adjustment ring until it meets the upper external adjustment ring. Tighten firmly to prevent
slippage that might lead to inconsistencies in sample volume.

The lower external adjustment ring and O-ring are used to lock the upper external adjustment ring in place to prevent slippage
and subsequent changes in the sample volume during sampling.

6. Turn ON and actuate the hydraulic or pneumatic supply to collect a sample from the sample outlet to ensure that the
sample volume collected is the same as the desired sample volume.

Welker recommends the Welker Checkpoint™ Sample Bite Verification Panel for use with this unit.

7. As necessary, repeat steps 1–6 to further adjust the sample volume.
9IOM-195 MODEL: INLOOP™ ACE REV: B 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331

2.3 Preparing the Unit for Installation
1. Determine the direction of product flow in the fast loop.
2. Look through the spool to visually determine if the collection head is in correct alignment. The opening in the collection
head should face the direction of product flow so that the flowing stream will pass through the opening (Figure 5).

Figure 5: Aligning the Collection Head

3. If the opening in the collection head faces the direction of product flow, proceed to Section 2.4, Installing the Unit. If the
opening in the collection head does not face the direction of product flow, continue to step 4.
4. Remove the nuts and bolts from the flange, and then turn the sampler within the spool until the opening in the
collection head faces the direction of product flow and the flange holes align with the holes in the mating spool flange.
5. Look through the spool to visually ensure that the collection head is in correct alignment. If correct alignment has been
achieved, continue to step 6. It the collection head is still misaligned, repeat steps 4–5.
6. Following a cross-bolting sequence, install the bolts and nuts to the flange to secure it to the spool (Figure 6).

Figure 6: 8-Bolt Cross-Bolting Sequence
2.4 Installing the Unit

The fast loop must be depressurized prior to installing and removing the unit.

1. Close all valves on the inLoop™ ACE.
2. Position an appropriately sized gasket on the mating flange connection for the product inlet spool flange (Figure 2).
3. Install the product inlet spool flange to its mating flange connection.
10 IOM-195 MODEL: INLOOP™ ACE REV: B 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331