Welker AD905BU User manual

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

TABLEOFCONTENTS
2IOM-189 MODEL: INFLOW™ ACE MANUAL INSERTION REV: G 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®, WelkerJet®, 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 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 Tool 30
3.3 Maintenance: inFlow™ ACE 32
3.4 Troubleshooting 40
  
 APPENDICES 42
 A: Referenced or Attached Documents 42
 B: D-Style Collection Head Maintenance 43
 C:C-Style Collection Head Maintenance 45


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-189 MODEL: INFLOW™ ACE MANUAL INSERTION REV: G 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 can be safely inserted and
retracted manually in up to 40 psig or automatically with the optional insertion tool 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 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 optional external sample volume adjustment and insertion tool simplify 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. The optional insertion tool is integral to smooth insertion and retraction of the unit.Though
easily removable, the insertion tool can remain attached to the inFlow™ ACE without adding bulk.

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-189 MODEL: INFLOW™ ACE MANUAL INSERTION REV: G 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.
5IOM-189 MODEL: INFLOW™ ACE MANUAL INSERTION REV: G 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331

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, Anodized Aluminum Upper Housing,
Carbon Steel Lubricator Body, PTFE, Viton® Wetted Seals, and Buna 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)
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 ¼" FNPT
Motor Housing Actuation Ports
¼" FNPT
½" FNPT
³⁄₈" FNPT (Standard)
Insertion Length 0–24" (0–60 cm)
0–36" (0–91 cm)
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 (Standard)
C-Style Collection Head: 3–24 cc
Features
External Sand Relief
Purge Tube
V-ring Packing
Options
External Adjustment
Hydraulic Hand Pump
Insertion Tool
NACECompliance
6IOM-189 MODEL: INFLOW™ ACE MANUAL INSERTION REV: G 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331

1.5 Equipment Diagrams
Figure 1: inFlow™ ACE Diagram
7IOM-189 MODEL: INFLOW™ ACE MANUAL INSERTION REV: G 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331

Figure 2: inFlow™ ACE Connections Diagram
8IOM-189 MODEL: INFLOW™ ACE MANUAL INSERTION REV: G 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331

Figure 3: inFlow™ ACE With Optional Insertion Tool Diagram
9IOM-189 MODEL: INFLOW™ ACE MANUAL INSERTION REV: G 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331

Figure 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

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.
SECTION 2: INSTALLATION&OPERATION
11 IOM-189 MODEL: INFLOW™ ACE MANUAL INSERTION REV: G 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331

2.2 Setting the Sample Volume

If the inFlow™ ACE is not equipped with the optional external adjustment assembly, the sample volume must be set prior to
installation.
If the inFlow™ ACE is equipped with the optional external adjustment assembly, the sample volume can be set at any time.

1. If the inFlow™ ACE is not equipped with the optional external adjustment assembly, continue to step 2 for instructions
on setting the sample volume. If the inFlow™ ACE is equipped with the optional external adjustment assembly,
proceed to step 6 for instructions on setting the sample volume.
Setting the Sample Volume at the Collection Head

Welker can pre-set the sample volume if noted at the time of order.
Figure 5: D-Style Collection 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 full rotation of the collection head is approximately:
• 0.4 cc if the inFlow™ ACE is equipped with the D-Style collection head.
• 1 cc if the inFlow™ ACE is equipped with the C-Style collection head.

5. Once the desired sample volume has been reached, firmly tighten the jam nut on the collection head to prevent
slippage that might lead to inconsistencies in the sample volume.
12 IOM-189 MODEL: INFLOW™ ACE MANUAL INSERTION REV: G 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331

Setting the Sample Volume Using the Optional External Adjustment
6. Locate the exposed external adjustment chamber in the motor top (Figure 7).

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 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, Sugar Land, TX 77498 welker.com Service Department 281.491.2331

Figure 8: Setting the External Adjustment Rings

8. Begin with the upper external adjustment ring at the top of the external adjustment body (Figure 8).

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.

9. Using the provided external adjustment tool, turn the upper adjustment ring to the desired volume (Figure 8).

One full rotation of the upper external adjustment ring is approximately 1 cc if the inFlow™ ACE is equipped with the D-Style
collection head. Each hole in the upper external adjustment ring is equal to approximately 0.10 cc.

10. 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 the 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.

11. 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.

12. As necessary, repeat steps 6–11 to further adjust the sample volume.
14 IOM-189 MODEL: INFLOW™ ACE MANUAL INSERTION REV: G 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331

2.3 Preparing the Unit for Installation
Installing the External Sand Relief and Sample Outlet Flexline
Figure 9: External Sand Relief and Sample Outlet Flexline Installation
1. Prior to installing the inFlow™ ACE to the pipeline, the external sand relief and sample outlet flexline must be installed.

DONOT install or operate the unit without first installing the external sand relief and sample outlet flexline. The external sand
relief is a safety relief valve required for safe installation and operation of the unit. Failure to install the external sand relief and
sample outlet flexline prior to installation and operation could damage the unit, injure the operator, or allow product to free
flow unchecked.

2. Lay the inFlow™ ACE on a smooth, clean surface.
3. Wrap the exposed threads on the external sand relief with PTFEtape.
4. Screw the external sand relief into emergency shutoff valve E (Figure 9).
5. Screw the loose 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 collar must be loose in order to pull the collection head out of the lubricator body.

9. Loosen the jam nut, and then turn the hanger (Figure 5 or Figure 6). The opening in the collection head should face the
direction of product flow so that the flowing stream will pass through the opening.
10. Tighten the jam nut on the collection head (Figure 5 or Figure 6). The tightened jam nut and safety wire will prevent the
collection head from turning.
11. Align the alignment indicator rod on the lock collar with the opening in the collection head. This should bring the lock
collar into alignment with the lockdown studs on the lubricator body.

15 IOM-189 MODEL: INFLOW™ ACE MANUAL INSERTION REV: G 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331

Once the unit is installed to the pipeline, the alignment indicator rod 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

Setting the Insertion Length
12. Prior to installing the inFlow™ ACE, the length the insertion shaft will need to travel inside the pipeline must be determ-
ined. 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 11). This will be the 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 mark this point.

17 IOM-189 MODEL: INFLOW™ ACE MANUAL INSERTION REV: G 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331

Figure 12: Setting 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

Figure 13: Lock Collar Diagram

16. Loosen the cap screws on the sides of the lock collar (Figure 13).
17. Carefully slide the lock collar up the shaft to the shaft insertion length, taking care not to scratch the outer shaft.
18. Ensure that the alignment indicator rod is still aligned with 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 collar and that the lock collar will
hold the probe in place when under pressure.
19 IOM-189 MODEL: INFLOW™ ACE MANUAL INSERTION REV: G 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331

2.4 Installing the Unit

DONOT install or operate the unit without first installing the external sand relief and sample outlet flexline. The external sand
relief is a safety relief valve required for safe installation and operation of the unit. Failure to install the external sand relief and
sample outlet flexline prior to installation and operation could damage the unit, injure the operator, or allow product to free
flow unchecked.

1. Close all valves on the inFlow™ ACE.
2. Secure the inFlow™ ACE to a full port pipeline isolation valve.

For long probes installed horizontally, Welker recommends field installation of bracing support for the outlet end of the probe
to offset the cantilever effect and prevent bending of the shaft. Any bracing or support installed should NOT contact the probe
shaft, as scratching or other damage to the shaft may lead to loss of integrity of the sealing surface.

Lubricator vent (drain) valve C on the lubricator body must be pointed down.

If the unit will be inserted manually, continue to step 3.
If the unit will be inserted using the optional insertion tool, proceed to step 7.
ManualInsertion

At pressures above 40 psig, the inFlow™ ACE cannot be safely inserted or retracted manually. To insert the inFlow™ ACE, the
pipeline pressure will need to be reduced to 40 psig or below.

At least two (2) people are required to correctly and safely insert the inFlow™ ACE into the pipeline.

3. Slowly open the pipeline isolation valve. Check for leaks and repair as necessary.
4. Using the alignment indicator rod, manually insert the shaft slowly into the pipeline. The alignment indicator rod should
be parallel to the pipeline.
5. Secure the inFlow™ ACE in place by guiding the lock collar over the lockdown studs on the lubricator body and firmly
tightening the hex nuts (Figure 13).

DONOT release the inFlow™ ACE until the lock collar has been secured to the lubricator body.

If the lock collar does not align with the lockdown studs, the inFlow™ ACE may be out of alignment. See Section 2.3, Preparing
the Unit for Installation, for instructions on properly aligning the unit.

20 IOM-189 MODEL: INFLOW™ ACE MANUAL INSERTION REV: G 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331