Welker AD887AC User manual
INSTALLATION, OPERATION, ANDMAINTENANCEMANUAL
WELKER INFLOW™ ACE CRUDEOILSAMPLER
FIXEDINSERTION
DRAWING NUMBER
AD887AC
MANUAL NUMBER
IOM-178
REVISION
Rev. A, 11/8/2019
TABLEOFCONTENTS
2IOM-178 MODEL: INFLOW™ ACE FIXEDINSERTION REV: A 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 4
1.4 Specifications 5
1.5 Equipment Diagrams 6
2. INSTALLATION & OPERATION 7
2.1 Before You Begin 7
2.2 Installing the Unit 7
2.3 Setting the Sample Volume 9
2.4 Operating the Unit 12
2.5 Purging the Unit 13
2.6 Emergency Shutoff 14
2.7 Removing the Unit 14
3. MAINTENANCE 15
3.1 Before You Begin 15
3.2 Maintenance 16
3.3 Troubleshooting 23
APPENDICES 25
A: Referenced or Attached Documents 25
B: D-Style Collection Head Maintenance 26
IMPORTANTSAFETYINFORMATION
READALLINSTRUCTIONS
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.
BEFOREYOUBEGIN
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-178 MODEL: INFLOW™ ACE FIXEDINSERTION REV: A 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 OilSampler is a direct-mount isokinetic probe sampler designed to extract a representative
sample of liquid product from the flowing stream. 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.
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 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.
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.
SECTION 1: PRODUCTINFORMATION
4IOM-178 MODEL: INFLOW™ ACE FIXEDINSERTION REV: A 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, Carbon Steel Lubricator Body and Non-Wetted
Parts, PTFE, Kalrez® 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)
Pipeline Connection Size: 1" or 2"
Rating: 150, 300, or 600 ANSIRF
Sample Outlet Connection ¼" FNPT
Motor Housing Actuation Ports ½" FNPT
³⁄₈" FNPT (Standard)
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
Options Pipeline Spool With Mixer
NACE Compliance
5IOM-178 MODEL: INFLOW™ ACE FIXEDINSERTION REV: A 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331
1.5 Equipment Diagrams
Figure 1: inFlow™ ACE Diagram
Figure 2: inFlow™ ACE Connections Diagram
6IOM-178 MODEL: INFLOW™ ACE FIXEDINSERTION REV: A 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.
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.
2.2 Installing the Unit
The pipeline must be depressurized prior to installing and removing the unit.
1. Close all valves on the inFlow™ ACE.
2. Using a felt tip pen, mark the location of the opening in the hanger on the motor housing.
Once the unit is installed to the pipeline, the mark on the motor housing will be an external reference point to the collection
head opening.
3. Determine the direction of product flow in the pipeline.
4. Install the inFlow™ ACE to the pipeline so that the opening in the collection head faces the direction of product flow, as
this allows the flowing stream to pass through the opening (Figure 3). As necessary, refer to the mark on the motor
housing to ensure the inFlow™ ACE is installed correctly.
SECTION 2: INSTALLATION&OPERATION
7IOM-178 MODEL: INFLOW™ ACE FIXEDINSERTION REV: A 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331
Figure 3: Correct inFlow™ ACE Installation
5. Secure the inFlow™ ACE to the pipeline.
6. Using ¼" tubing, connect from the sample outlet to an appropriate customer-supplied sample container, such as a
Welker TCC Transportable Crude Oil Container.
Customer-supplied ¼" tubing must slope downward from the inFlow™ ACE to the sample container.
7. Use appropriately sized tubing to connect from the normally open port on the solenoid to port A on the motor housing
(Figure 2). Use appropriately sized tubing to connect from the normally closed port on the solenoid to port B on the
motor housing (Figure 2).
The normally open port should be stamped "A" or "NO."
The normally closed port should be stamped "B" or "NC."
8. Pressurize the pipeline.
9. Open emergency shutoff valve E (Figure 1).
10. Adjust the external sand relief. With emergency shutoff valve E open, loosen the jam nut, tighten the adjusting screw on
the external sand relief until no product emerges from the outlet, and then tighten the jam nut as a locking device
(Figure 10).
After the external sand relief valve has been set, emergency shutoff valve E must remain open during sampling. For more
information about emergency shutoff valve E, see Section 2.6, Emergency Shutoff.
The external sand relief comes factory-set by the manufacturer if requested at the time of order.
8IOM-178 MODEL: INFLOW™ ACE FIXEDINSERTION REV: A 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331
2.3 Setting the Sample Volume
1. To set or adjust the sample volume, locate the external adjustment assembly, and then slide the dustcover down to
expose the external adjustment chamber (Figure 4).
Setting the sample volume is accomplished by:
• determining where the adjustment pin will need to be placed to attain the desired sample volume,
• rotating the upper external adjustment ring in relation to the adjustment pin setting to attain the desired sample
volume, and
• installing the adjustment pin to the predetermined slot.
The sample volume is determined by the distance between the upper external 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 4: Upper Housing Diagram
2. Determine to which slot the adjustment pin will be installed after the external adjustment rings have been set (Figure
5).
9IOM-178 MODEL: INFLOW™ ACE FIXEDINSERTION REV: A 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331
Figure 5: Determining Adjustment Pin Setting
3. Begin with the lower external adjustment ring at the bottom of the external adjustment chamber and the upper
external adjustment ring tightened down on top of it (Figure 6).
Figure 6: Setting the External Adjustment Rings
10 IOM-178 MODEL: INFLOW™ ACE FIXEDINSERTION REV: A 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331
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 external adjustment ring to the desired volume (Figure 6).
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.
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. Slide the dustcover up to cover the external adjustment chamber (Figure 4).
7. Install the adjustment pin through the dustcover to the appropriate slot.
8. 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.
9. As necessary, repeat steps 1–8 to further adjust the sample volume.
11 IOM-178 MODEL: INFLOW™ ACE FIXEDINSERTION REV: A 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331
2.4 Operating the Unit
1. Turn ONthe hydraulic or pneumatic supply.
2. As necessary, adjust the hydraulic or pneumatic supply to 100 psig.
3. Set the timer or controller to actuate the solenoid at the desired sampling actuation frequency based on the sampling
equations provided(Figure 7).
Figure 7: Sampling Frequency Equations
Never fill the container above 80% of its capacity. Allow at least 20% room for product expansion should the container be
exposed to increased temperatures.
Note the 0.8 in Equation 1 represents the 80% volume limit for liquid sampling.
4. Ensure that emergency shutoff valve E is open (Figure 1).
5. As necessary, turnon 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 air and fill the insertion shaft with product before sample
appears at the outlet port.
12 IOM-178 MODEL: INFLOW™ ACE FIXEDINSERTION REV: A 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331
6. 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.
2.5 Purging the Unit
The purge tube allows the sampler to be completely evacuated of sample from the inlet to the sample container. Automated
purging can be achieved with the Welker PNP Plug & Purge Panel.
To prevent cross-contamination between samples, Welker recommends that the inFlow™ ACE be evacuated, or purged,
following each sample batch to inject all sampled product remaining in the unit into the sample container.
1. Connect an appropriate customer-supplied nitrogen or other inert gas supply to purge valve P (Figure 1).
Welker recommends using nitrogen or helium as the inert gas supply.
2. Set the inert gas supply pressure to approximately 50 psig above the external relief on the inFlow™ ACE.
Prior to 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. TurnONthe inert gas supply.
4. Open purge valve P (Figure 1).
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 has been set too low and previous product remains in
the sampler.
If more than a burst of inert gas is heard entering the sample container, the purge pressure has been set too high and the
operator risks overpressurizing the sample container.
6. Turn off the inert gas supply.
7. Close purge valve P (Figure 1).
8. Disconnect the inert gas supply from purge valve P (Figure 1).
13 IOM-178 MODEL: INFLOW™ ACE FIXEDINSERTION REV: A 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331
2.6 Emergency Shutoff
Figure 8: Packing Adjustment Nut
1. If sample begins to free flow from the sample outlet, turn OFF the hydraulic or pneumatic supply to the motor, and then
close emergency shutoff valve E.
DONOT operate the pump after emergency shutoff valve E is closed. Operating the pump while emergency shutoff valve E is
closed may damage the pump.
Free flow from the sample outlet indicates that the external adjustable relief has not been set correctly or that 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.
2.7 Removing the Unit
1. Ensure that the inFlow™ ACE has been purged. See Section 2.5, Purging the Unit, for instructions on properly purging
the inFlow™ ACE.
2. Deactivate or turnOFF the hydraulic or pneumatic supply.
3. Depressurize, drain, 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.
6. Depressurize the pipeline.
The pipeline must be depressurized prior to installing and removing the unit.
7. The unit is now ready to be removed from the pipeline for maintenance or to be relocated.
14 IOM-178 MODEL: INFLOW™ ACE FIXEDINSERTION REV: A 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331
3.1 Before You Begin
1. 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.
2. 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.
3. All maintenance and cleaning of the unit should be performed on a smooth, clean surface.
4. Welker recommends having the following tools available for maintenance. Please note that the exact tools required may
vary by model.
a. Adjustable Wrench (Qty. 2)
b. Channel Lock Pliers
c. Hex Key Set
d. Seal Pick
e. Snap Ring Pliers
f. Welker Great Barrier Sealant™
SECTION 3: MAINTENANCE
15 IOM-178 MODEL: INFLOW™ ACE FIXEDINSERTION REV: A 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331
16 IOM-178 MODEL: INFLOW™ ACE FIXEDINSERTION REV: A 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331
3.2 Maintenance
1. Prior to performing maintenance, the inFlow™ ACE must be removed from the pipeline. See Section 2.7, Removing the
Unit, for instructions on removing the unit from the pipeline.
2. Relieve any trapped pressure by loosening the jam nut and turning the adjusting screw on the external sand relief
counterclockwise and opening purge valve P (Figure 9 and Figure 10).
3. Lay the inFlow™ ACE on a smooth, clean surface
Collection Head Assembly
4. As necessary, cut the safety wire from the relief cap to the lubricator body, and then remove the safety wire.
5. Unscrew and remove the collection head assembly from the lubricator body.
6. Refer to Appendix B, D-Style Collection Head Maintenance, for instructions on performing maintenance on the collection
head.
Purge Assembly
7. Unscrew the sample outlet flexline from the elbow above the sample outlet (Figure 9).
Figure 9: Outlet Assembly With Purge
8. Unscrew the purge assembly at the tee connecting it to the insertion shaft. Note that the long purge tube is attached to
the purge assembly and will be removed at this time. Take care not to bend or otherwise damage the purge tube.
9. Unscrew the external sand relief from emergency shutoff valve E.
10. Unscrew the flexline from the elbow in the external sand relief.
11. Unscrew the base of the external sand relief from the body (Figure 10).
17 IOM-178 MODEL: INFLOW™ ACE FIXEDINSERTION REV: A 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331
Figure 10: External Sand Relief Maintenance Diagram
12. Replace the O-ring on the base.
13. Unscrew the jam nut from the adjusting screw.
14. Inspect the poppet for scratches or other damage. If scratches or other damage are present on the poppet (face) seat,
replace the poppet.
15. Reassemble the external sand relief.
16. Screw the external sand relief into emergency shutoff valve E (Figure 9).
17. Screw the flexline into the elbow in the external sand relief (Figure 9).
18 IOM-178 MODEL: INFLOW™ ACE FIXEDINSERTION REV: A 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331
Disassembling the Upper Housing
18. Unscrew the machine screws from the top cap and carefully remove the top cap from the motor housing (Figure 12).
19. Unscrew the packing gland assembly from the lubricator body.
20. Unscrew the packing gland body from the motor housing, and then carefully remove the packing gland body from the
insertion shaft. Take care not to scratch or otherwise damage the insertion shaft assembly.
21. 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 11). Take care not to misplace the pins that align the lock collars with
the external adjustment body.
Figure 11: External Adjustment Assembly
22. Carefully slide the external adjustment body off the insertion shaft. Take care not to scratch or otherwise damage the
insertion shaft assembly.
23. Carefully pull the insertion shaft out through the motor housing.
19 IOM-178 MODEL: INFLOW™ ACE FIXEDINSERTION REV: A 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331
Motor Housing Assembly
Figure 12: Motor Housing Assembly
24. Replace the O-rings and back ups on the top cap.
25. Inspect the wiper ring in the top cap. Replace it if it shows signs of wear or damage.
26. Replace the O-ring and crown seal on the piston.
27. Replace the O-ring and back ups in the motor housing.
28. Inspect the wiper ring in the motor housing. Replace it if it shows signs of wear or damage.
29. Inspect the polished portion of the insertion shaft. If any scratches or damage are present, repair or replace as necessary.
20 IOM-178 MODEL: INFLOW™ ACE FIXEDINSERTION REV: A 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department 281.491.2331
Packing Gland Body
Figure 13: Packing Gland Assembly
30. Replace the O-rings on the packing gland body.
31. Remove the plug from the lubrication port, and then slide the gland cover off the packing gland body.
32. Unscrew the packing adjustment nut from the packing gland body.
33. Inspect the wiper ring in the packing adjustment nut. Replace it if it shows signs of wear or damage.
34. 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.
35. Remove the cartridge seal body from the packing gland body.
36. Install a replacement cartridge seal body to the packing gland body.
37. Screw the packing adjustment nut into the packing gland body.
38. Replace the O-ring in the packing gland body.
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