Welker® OdorEyes® ECOsystem™ Pulse Bypass System Installation, Operation, Maintenance Manual

INSTALLATION, OPERATION, AND MAINTENANCE MANUAL WELKER® ECOSYSTEM™ PULSE BYPASS SYSTEM US PATENT 6,142,162 DRAWING NUMBERS OE153VS OE180VS.1 OE181VS OE181VS.3E OE183VS.1E OE190VS OE220VS.1E MANUAL NUMBER IOM-181 REVISION Rev. B, 07/29/2016 TABLE OF CONTENTS SAFETY 3 1. PRODUCT INFORMATION 4 1.1 Introduction 4 1.2 Product Description 4 1.3 Safety Warning 4 1.4 Specifications 5 1.5 Equipment Diagrams 6 2. INSTALLATION & OPERATION 16 2.1 Before You Begin 16 2.2 Installation 16 2.3 Start-Up Procedures 17 3. TOUCH SCREEN CONTROLLER 19 3.1 Understanding the Display 19 3.2 Navigating the Monitor Screens 20 3.3 Navigating the Setup Screens 27 4. MAINTENANCE 45 4.1 Before You Begin 45 4.2 Maintenance 45 APPENDICES 46 A: Referenced or Attached Documents 46 B: Maintenance Schedule 47 Welker®, Welker Jet®, WelkerScope®, and OdorEyes® are Registered Trademarks owned by Welker, Inc. 2 IOM-181 | MODEL: ECOSYSTEM™ | REV: B 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 SAFETY 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® OdorEyes® ECOsystem™ Pulse Bypass System. 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® OdorEyes® 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 ECOsystem™ Pulse Bypass System is of a mechanical and electrical 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 ECOsystem™ Pulse Bypass System, please contact a Welker® representative immediately. Phone: 281.491.2331 Address: 13839 West Bellfort Street Sugar Land, TX 77498 3 IOM-181 | MODEL: ECOSYSTEM™ | REV: B 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 SECTION 1: PRODUCT INFORMATION 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® OdorEyes® 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® OdorEyes® ECOsystem™ Pulse Bypass System is designed to infuse the customer pipeline proportional to flow with natural gas that has been supersaturated with vaporized odorant. This skid-mounted automatic bypass system has three (3) primary components: the touch screen controller, the valve section, and the odorant supply tank. Each primary component plays an integral role in the operation of the ECOsystem™ and can be customized to better suit each application. The touch screen controller serves as the system’s brain. It continuously receives feedback from the customer’s gas flow meter and the flow switch in the valve section, allowing the system to respond to changing flow conditions. As pipeline conditions change, the controller increases or decreases the injection rate so that the ECOsystem™ continues infusing proportional to flow. On-site and remote troubleshooting and monitoring are made easier by time- and date-stamped audit data detailing system performance, alarm history, and odorant tank level. An optional solar panel generates renewable energy to power the system when an electrical source is unavailable. The valve section contains one (1), two (2), or three (3) solenoids, which control the flow of gas through the odorant supply tank and into the pipeline. Having two (2) or three (3) solenoids allows the ECOsystem™ to better respond to and accommodate varying flow rates and limits interruption to operation in the event of solenoid maintenance. To prolong the operational life of the regulator and solenoid(s), the Welker® F-5 Filter/Dryer conditions the natural gas supply. The flow switch communicates the solenoid operation to the controller to ensure proper odorization. For pulse bypass systems used in cold climates, a heater with thermostat can be added to replenish heat lost during regulation. Each odorant supply tank is equipped with a tank fill inlet, vent port, blanket pressure inlet, level gauge, and outlet to the pipeline. The temperature transmitter communicates odorant temperature to the controller so the system can compensate for temperature changes within the odorant tank. For added automation, an electronic level transmitter can be installed to communicate tank level to the controller. Regardless of volume or orientation, the odorant supply tank comes with 110% containment that is sloped to the drain for easy draining. Welker may custom design the ECOsystem™ Pulse Bypass System to suit the particular application and specifications of each customer. 1.3 Safety Warning Wherever hazardous gases or vapor-producing liquids are used, transported, or stored, the potential for an accidental leak exists. Continuous monitoring of these hazards is essential to ensure personnel safety. 4 IOM-181 | MODEL: ECOSYSTEM™ | REV: B 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: ECOsystem™ Specifications Vaporized Odorant Infusion AC 120 V DC 12 V DC 24 V 5 US Gallons 20 US Gallons 50 US Gallons 60 US Gallons 100 US Gallons 120 US Gallons 250 US Gallons 500 US Gallons Others Available Odorant Tank Level Gauge Skid With 110% Containment Temperature Transmitter Touch Screen Controller Valve Section (See Table 2) US Patent 6,142,162 Heater for Controller Enclosure NEMA 4 or NEMA 7 Enclosure for Controller Solar Panel Steel Building Application Electrical Connection Odorant Tank Volume Features Patent Options Table 2: Valve Section Specifications ¼" (for Low Flow) ³∕8" (for High Flow) ¼" and ³∕8" (for Variable Flow) 2-Way Solenoid Valve Flow Switch Regulator for Natural Gas Supply Welker® F-5 Filter/Dryer for Natural Gas Supply Backup Solenoid Enclosure Heater With Thermostat Low Flow Solenoid Volume Bottle (for Systems With ³∕8" Tubing) Tubing Size Features Options 5 IOM-181 | MODEL: ECOSYSTEM™ | REV: B 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 1.5 Equipment Diagrams Figure 1: General Arrangement – Horizontal Odorant Tank 6 IOM-181 | MODEL: ECOSYSTEM™ | REV: B 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 Figure 2: General Arrangement – Vertical Odorant Tank 7 IOM-181 | MODEL: ECOSYSTEM™ | REV: B 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 Figure 3: Valve Section – Single Solenoid, ³∕8" Tubing 8 IOM-181 | MODEL: ECOSYSTEM™ | REV: B 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 Figure 4: Valve Section – Dual Solenoid, ³∕8" Tubing 9 IOM-181 | MODEL: ECOSYSTEM™ | REV: B 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 Figure 5: Valve Section – Dual Solenoid With Heater, ³∕8" Tubing 10 IOM-181 | MODEL: ECOSYSTEM™ | REV: B 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 Figure 6: Valve Section – Single Solenoid, ¼" Tubing 11 IOM-181 | MODEL: ECOSYSTEM™ | REV: B 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 Figure 7: Valve Section – Dual Solenoid, ¼" Tubing 12 IOM-181 | MODEL: ECOSYSTEM™ | REV: B 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 Figure 8: Valve Section – Dual Solenoid With Heater, ¼" Tubing 13 IOM-181 | MODEL: ECOSYSTEM™ | REV: B 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 Figure 9: Valve Section – Triple Solenoid With Heater, ¼" and ³∕8" Tubing 14 IOM-181 | MODEL: ECOSYSTEM™ | REV: B 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 Figure 10: Pneumatic Filter Figure 11: Inert Gas Supply Tank (Applicable for Valve Section With ³∕8" Tubing) 15 IOM-181 | MODEL: ECOSYSTEM™ | REV: B 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 SECTION 2: INSTALLATION & OPERATION 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. The ECOsystem™ will ship skid-mounted and “hard-tube” connected with manufacturer-supplied fittings and hardware. However, the customer will need to supply some tubing and fittings in order to complete the installation of the system. The ECOsystem™ must be installed in a section of the natural gas pipeline with a regulated pressure drop, such as a regulator station or gate station. 2.2 Installation System Skid 1. 2. 3. Mount the skid to a flat, level surface, such as a concrete slab. Connect a grounding wire to each grounding lug on the skid to safely ground the system. Connect the skid drain port(s) to an appropriate draining location. System Connections 4. Using appropriately sized customer-supplied tubing, connect from the outlet of the pipeline upstream of the regulated pressure drop to the inlet of the Welker® F-5 Filter/Dryer (Figure 10). Tubing must have a minimum diameter of ³∕8". 5. Connect from odorized gas outlet valve K2 to an unused valve on the natural gas pipeline downstream of the regulated pressure drop (Figure 1 or Figure 2). Welker recommends using stainless steel tubing for all natural gas process lines, as plastic tubing can absorb odorant from the gas. 6. 7. 16 Ensure that all valves on the system are closed. Ensure that all fittings, connections, and bolts are tightened. IOM-181 | MODEL: ECOSYSTEM™ | REV: B 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 Electrical Connections Turn OFF the electrical supply prior to making electrical connections. 8. Connect an appropriate electrical supply to the controller. Refer to the industry standards for appropriate electrical connections to interface with the PLC. For systems used in hazardous locations, sealing compound is required to seal all fittings to restrict the passage of gases, vapors, or flames. 9. Connect the customer gas flow signal device to the termination block. The controller can accept analog or pulse input. 2.3 Start-Up Procedures Odorant Supply Tank 1. 2. Open emergency bypass valves B1 and B2 (Figure 3 to Figure 9). Fill the odorant supply tank in accordance with company policy and procedure, taking care not to exceed 80% of the total volume of the supply tank. Never fill the odorant supply tank above 80% of its capacity. Allow at least 20% for product expansion, should the tank be exposed to increased temperatures. 3. 4. Check the odorant supply tank for leaks and repair as necessary. Close emergency bypass valves B1and B2 (Figure 3 to Figure 9). Natural Gas Supply Regulator 5. 6. 7. As necessary, open any valves between the outlet on the natural gas pipeline and the F-5 inlet. Open F-5 inlet valve E and F-5 outlet valve F (Figure 10). Apply natural gas to the valve section to pressurize the natural gas supply regulator (Figure 3 to Figure 9). The pneumatic supply regulator comes factory-set to the setting required to operate the solenoid(s). 8. 9. If applicable, open regulator outlet valve C (Figure 8 or Figure 9). If applicable, open volume bottle valve D (Figure 11). The volume bottle will fill with the conditioned natural gas. Only systems with ³∕8" tubing are equipped with a volume bottle. 17 IOM-181 | MODEL: ECOSYSTEM™ | REV: B 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 Valve Configuration 10. Slowly open the valves indicated in Table 3. Table 3: Start-Up Valve Orientation Valve Description Blanket Pressure Outlet Blanket Pressure Inlet Odorized Gas Outlet Valve Letter A J1 & J2 K1 & K2 Reference Figures 3–9 1&2 1&2 Once odorized gas outlet valves K1 and K2 are open, gas may free flow from the odorant supply tank to the pipeline until pressure in the system equalizes. Note that free flow will last only for a short time and over-odorization will not occur. 11. 12. If applicable, slowly open any valves between the odorized gas outlet on the odorant supply tank and the pipeline. Check for leaks and repair as necessary. Controller Configuration 13. Verify that the customer set points have been correctly set by the manufacturer. Verifying Solenoid and Flow Switch Operation 14. 15. 16. 17. 18 From the controller, verify the correct operation of the solenoid and flow switch. From the Main Menu, select Setup Odorizer (Figure 23). From the Setup Odorizer menu, select View I/O (Figure 41). As the controller opens the solenoid, verify that FlowSw and Sol 1 darken simultaneously. As the controller closes the solenoid, verify that FlowSw and Sol 1 clear simultaneously. Once the correct operation of the solenoid and flow switch has been confirmed, the ECOsystem™ is operational. IOM-181 | MODEL: ECOSYSTEM™ | REV: B 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 SECTION 3: TOUCH SCREEN CONTROLLER 3.1 Understanding the Display The touch screen controller is used to modify system parameters and view current system information and current alarm status. The touch screen controller is a menu-driven system. The Main Menu screen is the top screen in the menu tree (Figure 12). Figure 12: Controller Menu Tree 19 IOM-181 | MODEL: ECOSYSTEM™ | REV: B 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 Navigating the Display Figure 13: Navigation Keys 3.2 Navigating the Monitor Screens Through the monitor screens, the user can access the System Status, Solenoid Stats, Odorant Tank Level, Current Alarms, Audit Trail, Alarms Log, Controller Version, and MicroSD Card to view current information for the odorizer. Monitor screens are informational screens: no values can be changed from these screens. Figure 14: Monitor Odorizer Submenus 20 IOM-181 | MODEL: ECOSYSTEM™ | REV: B 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 System Status The System Status submenus provide the user with an overview of system performance. Figure 15: System Status Submenu If the system status totals are used to track system performance, they should be periodically reset through the Controller Setup submenu (Figure 24). As the total values increase, they will begin to lose accuracy and will eventually stop accumulating. 21 IOM-181 | MODEL: ECOSYSTEM™ | REV: B 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 Solenoid Stats Figure 16: Solenoid Stats Submenu Odorant Tank Level Figure 17: Odorant Tank Level Submenu 22 IOM-181 | MODEL: ECOSYSTEM™ | REV: B 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 Viewing the Current Alarms Figure 18: Current Alarms Screen Analog Gas Flow Pulse Gas Flow Constant Rate Mode Shutdown Mode Fixed Mode Analog Temperature Analog Tank Level Tank Low Level Odorant Overflow Odorant No Flow 23 IOM-181 | Table 4: Current Alarms Can only be active if Analog mode is selected. The controller will go into the selected fail mode when this alarm is active. NOTE: If this alarm is active, verify that a 4–20 mA signal is being received from the flow meter. Can only be active if Pulse mode is selected. The controller will go into the selected fail mode when this alarm is active. NOTE: If this alarm is active, the pulse input cutoff time has expired. Verify that a pulse input is being received from the flow meter. If this alarm is active when the controller is receiving pulse input from the flow meter, Welker recommends increasing the pulse input cutoff time to prevent the alarm from becoming active prematurely. Can only be active if Constant Rate Mode is specified as the desired fail mode. The controller will enter this gas flow fail mode when there is a gas flow signal loss. Can only be active if Shutdown Mode is specified as the desired fail mode. The controller will enter this gas flow fail mode when there is a gas flow signal loss. Can only be active if Fixed Mode is enabled and the Fixed Alarm Rate is set. NOTE: If this alarm is active, the Fixed Alarm Rate will be the assumed gas flow in the system and will override any other input parameters. The Fixed Rate Alarm will not clear until Fixed Mode is disabled. Can only be active if Transmitter is set as the RTD setup method. NOTE: If this alarm is active, verify that a 4–20 mA signal is being received from the temperature transmitter. If this alarm is active, the system will use the manually entered temperature; therefore, Welker recommends regularly updating the manual temperature value. Can only be active if an electronic level transmitter is used to track the odorant tank level and the controller loses the 4–20 mA signal from the transmitter. NOTE: If this alarm is active, the controller will automatically switch to the odorant flow method to track the odorant tank level. The controller will use the value of odorant in the tank and subtract the appropriate volume each time the solenoid opens. Active if the odorant tank level has dropped below the specified value. NOTE: This alarm will clear once the tank is filled with odorant or the alarm set point is lowered. Active if the flow switch signals the controller indicating gas is passing through it even though the solenoid(s) should not be open. NOTE: If this alarm is active, it could be an indication that a solenoid is stuck open and that the system is over-odorizing or that the flow switch is stuck open. Active if the controller signals the solenoid to open but does not receive a signal from the flow switch confirming the solenoid has opened. NOTE: If this alarm is active, it could be an indication that the solenoid has failed closed or that the pressure differential across the system is not great enough to odorize. MODEL: ECOSYSTEM™ | REV: B 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 View Audit Trail From the View Audit Tail submenu, the user can access the audit tail records stored on internal memory. Up to 600 audit trail records can be stored and viewed. Figure 19: View Audit Trail 24 IOM-181 | MODEL: ECOSYSTEM™ | REV: B 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 View Audit Trail From the View Alarms Log submenu, the user can access the alarms log stored on internal memory. Up to 428 alarms log records can be stored and viewed. Figure 20: View Alarms Log 25 IOM-181 | MODEL: ECOSYSTEM™ | REV: B 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 Controller Version Figure 21: Controller Version MicroSD Card Access Figure 22: MicroSD Card Access 26 IOM-181 | MODEL: ECOSYSTEM™ | REV: B 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 3.3 Navigating the Setup Screens Through the Setup Odorizer submenu, the user can access the Controller Setup, Odorant Tank Setup, Gas Flow Signal, Fixed Rate Setup, Auto Scroll Setup, MODBUS Setup, Local Audit Trail, Local Alarms Log, and View I/O submenus and change numeric and/or text values that alter the parameters and features of the odorizer. Changing numeric and/or text values in the Setup Odorizer submenus will alter how the system operates. Figure 23: Setup Odorizer Submenus 27 IOM-181 | MODEL: ECOSYSTEM™ | REV: B 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 Changing Values on Setup Screens Numeric Values 1. 2. 3. To change a numeric value, use the arrows to highlight the value to be changed, and then press ENTER (Figure 13). A keypad will appear on the screen. Type the new numeric value using the keypad. Once the new numeric value has been entered, press ENTER to save the changes. If the new value entered is outside the range of allowable values, the value will revert back to the previous value once ENTER is pressed. The keypad will stay active, allowing another value to be entered. Text Values 4. 5. 6. To change a text value, press on the value to be changed. A dropdown menu will appear on the screen. Scroll through the value’s options using the arrows in the dropdown menu. Highlight the desired text value, and then press ENTER to save the changes. If a mistake is made while entering the new value or if the value does not need to be changed, press ESC to discard the changes. 28 IOM-181 | MODEL: ECOSYSTEM™ | REV: B 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 Controller Setup Through the Controller Setup submenu, the user can set the general parameters for the odorizer. Figure 24: Controller Setup Submenu If the system status totals are used to track system performance, they should be periodically reset through the Controller Setup submenu (Figure 24). As the total values increase, they will begin to lose accuracy and will eventually stop accumulating. 29 IOM-181 | MODEL: ECOSYSTEM™ | REV: B 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 Figure 25: Dual Solenoid Setup Odorant Tank Setup Through the Odorant Tank Setup submenus, the user can input information for the odorant tank and temperature transmitter. Figure 26: Odorant Tank Setup Submenus 30 IOM-181 | MODEL: ECOSYSTEM™ | REV: B 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 Tank Level Setup Figure 27: Tank Level Setup When using an electronic level transmitter to track the odorant tank level, the Method should be set to Transmitter. When estimating the odorant tank level based on odorant usage, the Method should be set to Odorant Flow. The Current Level numeric value cannot be directly changed. Instead, the user must enter a value in the Adjust Level field to increase or decrease the Current Level by the specified amount. To decrease the Current Level, enter the volume to be subtracted from the current level as a negative number in the • Adjust Level field, and then press ENTER to save the changes. The Current Level should have decreased by the amount entered, and the Adjust Level should have reverted to 0.0. To increase the Current Level, enter the volume to be added to the current level in the Adjust Level field, and then press • ENTER to save the changes. The Current Level should have increased by the amount entered, and the Adjust Level should have reverted to 0.0. 31 IOM-181 | MODEL: ECOSYSTEM™ | REV: B 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 Figure 28: Strapping Tables 32 IOM-181 | MODEL: ECOSYSTEM™ | REV: B 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 RTD Setup Figure 29: RTD Setup When using a temperature transmitter to track the temperature in the odorant tank, the Method should be set to Transmitter. When there is no device tracking the temperature in the odorant tank, the Method should be set to Manual Entry. Setting an accurate manual temperature is necessary, even when using a temperature transmitter. The temperature of the odorant supply tank is key to system operation; correct odorization is not possible without this value. Odorant Type Setup Figure 30: Odorant Type Setup If the type of odorant used is changed, please contact Welker® OdorEyes® personnel for new absorption values and/or pressure regulator setting. 33 IOM-181 | MODEL: ECOSYSTEM™ | REV: B 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 Gas Flow Signal Through the Gas Flow Signal submenus, the user can set up the parameters of the odorant gas flow input signal. Figure 31: Gas Flow Signal Submenus 34 IOM-181 | MODEL: ECOSYSTEM™ | REV: B 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 Figure 32: Gas Flow Signal – Input Signal Setup If the gas flow signal will be analog, the analog signal must be 4–20 mA powered by the user. If the gas flow signal will be a pulse, the pulse will be a digital pulse powered by the controller. If the pulse input method is selected, the Pulse Input Cutoff must also be set (Figure 33). 35 IOM-181 | MODEL: ECOSYSTEM™ | REV: B 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 Figure 33: Gas Flow Signal – Fail Mode Setup Setting the Fail Mode to Shutdown will halt odorization until the alarm is cleared. Setting the Fail Mode to Constant Rate will allow odorization to continue at the specified rate. If the gas flow value does not change during the Pulse Input Cutoff time, the system will alarm for loss of flow and will enter the specified Fail Mode. The alarm will clear on the next pulse input or change in Modbus gas flow, and the system will resume normal operation. 36 IOM-181 | MODEL: ECOSYSTEM™ | REV: B 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 Fixed Rate Setup Figure 34: Fixed Rate Setup 37 IOM-181 | MODEL: ECOSYSTEM™ | REV: B 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 Auto Scroll Setup Figure 35: Auto Scroll Setup Figure 36: Auto Scroll Pre-Set Screens 38 IOM-181 | MODEL: ECOSYSTEM™ | REV: B 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 Modbus Setup Figure 37: Modbus Setup 39 IOM-181 | MODEL: ECOSYSTEM™ | REV: B 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 Audit Trail and Alarms Log Setup Through the Local Audit Trail and Local Alarms Log submenus, the user can set up and reset the data logs stored locally. Figure 38: Audit Trail and Alarms Log Setup 40 IOM-181 | MODEL: ECOSYSTEM™ | REV: B 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 SD Card Logging Figure 39: SD Card Logging 41 IOM-181 | MODEL: ECOSYSTEM™ | REV: B 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 View I/O The View I/O submenu provides the user with an overview of the current status of digital inputs, digital outputs, and analog inputs in the system. Figure 40: View I/O, 1 of 2 42 IOM-181 | MODEL: ECOSYSTEM™ | REV: B 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 Figure 41: View I/O, 2 of 2 43 IOM-181 | MODEL: ECOSYSTEM™ | REV: B 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 Date and Time Figure 42: Date and Time 44 IOM-181 | MODEL: ECOSYSTEM™ | REV: B 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 SECTION 4: MAINTENANCE 4.1 Before You Begin 1. 2. Refer to Appendix B, Maintenance Schedule, for the itemized Welker-recommended maintenance schedule for the ECOsystem™. 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. 4.2 Maintenance 1. 2. During operation, monitor the system for leaks. If leaks are present, halt operation and repair as necessary. Occasionally, a system component may need to be repaired or replaced for manufacturer recommended maintenance. To perform maintenance on components: a. Turn OFF all electrical power to the system. b. Depressurize the system and close all valves. Prior to closing odorized gas outlet valves K1 and K2 and/or the pipeline isolation valve, the ECOsystem™ must be powered down. This is to prevent the odorant supply tank from building pressure. c. d. e. f. 45 IOM-181 | Disconnect the tubing and remove individual system components for maintenance. For complete and proper maintenance on individual system components, refer to their respective Installation, Operation, and Maintenance (IOM) Manual. A list of component Installation, Operation, and Maintenance (IOM) Manuals is available in Appendix A, Referenced or Attached Documents, in this manual. After performing necessary maintenance on system components, reconnect all instrument tubing. Reinstall the system according to the instructions in Section 2.2, Installation, and Section 2.3, Start-Up Procedures. MODEL: ECOSYSTEM™ | REV: B 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 APPENDIX A: REFERENCED OR ATTACHED DOCUMENTS Welker® Installation, Operation, and Maintenance (IOM) Manuals suggested for use with this unit: • • • • IOM-025: Welker® IR-1, IR-2, IR-4, and IR-6 Instrument Regulators IOM-033: Welker® RV-1, RV-2, RV-2CP, and RV-3 Relief Valves IOM-046: Welker® F-4, F-5, F-19, F-23, and F-31 Filters/Dryers IOM-105: Welker® NV-1 and NV-2 Instrument Valves Other Installation, Operation, and Maintenance (IOM) Manuals suggested for use with this unit: • • • • • • • • • • • • • • • • • • • • • • • • ABB Inc. AT200 Magnetostrictive Level Transmitter (Welker® IOM-V011) ASCO Valve, Inc. 0.55 W Low Power Solenoid Valves Low Power Series (Welker® IOM-V267) ASCO Valve, Inc. 1.4 W Low Power Solenoid Valves Low Power Series (Welker® IOM-V266) ASCO Valve, Inc. General Service Solenoid Valves Series 8314 (Welker® IOM-V121) ASCO Valve, Inc. High Pressure Solenoid Valves Series 8223 (Welker® IOM-V103) CCI Thermal Technologies Inc. Cata-Dyne™ Explosion-Proof Gas Catalytic Heaters (Welker® IOM-V030) Fisher® 1301 Series High-Pressure Regulators Types 1301F and 1301G (Welker® IOM-V107) Gems™ Sensors & Controls Piston-Type Flow Switches Series FS-925/926 & FS-927/930 (Welker® IOM-V029) GE Oil & Gas Mooney Series 20/20S/20H/20HS Pilot Regulators (Welker® IOM-V101) Horner APG XLe/XLt OCS (Welker® IOM-V224) Inline Industries 201F Ball Valve (Welker® IOM-V222) INTERTEC™ CP MULTITHERM C Electric Heater (Welker® IOM-V104) INTERTEC™ TS Thermostat (Welker® IOM-V105) MTS Sensors Corporation Level Plus® Liquid-Level Sensors With Temposonics® Technology M-Series Model MR Analog Transmitter (Welker® IOM-V036) Power-Sonic Corporation PS-1270 12 Volt 7.0 AH Rechargeable Sealed Lead Acid Battery (Welker® IOM-V223) PR electronics 5333D 2-Wire Programmable Transmitter (Welker® IOM-V270) PR electronics PRetop 5331B 2-Wire Programmable Transmitter (Welker® IOM-V269) Saginaw Control & Engineering EL Enclosure SCE-30EL3012LP (Welker® IOM-V265) Solutions With Innovation Visual Level Indicator L505 Dip-Tape Visual Level Indicator (Welker® IOM-V037) Swagelok® Check Valves C, CA, CH, CP, and CPA Series (Welker® IOM-V076) Swagelok® One-Piece Instrumentation Ball Valves 40G Series and 40 Series (Welker® IOM-V085) Swagelok® Plug Valves P4T and P6T Series (Welker® IOM-V102) Swagelok® Proportional Relief Valves R Series (Welker® IOM-V086) WIKA Bourdon Tube Pressure Gauges Type 232.53 and Type 233.53 (Welker® IOM-V171) Welker® drawings and schematics suggested for use with this unit: • • • • • • • 46 System Drawing: OE153VS (Single Solenoid Valve Section, ³∕8" Tubing) System Drawing: OE180VS.1 (Dual Solenoid Valve Section, ³∕8" Tubing) System Drawing: OE181VS (Dual Solenoid Valve Section, ¼" Tubing) System Drawing: OE181VS.3E (Dual Solenoid Valve Section With Optional Heater, ¼" Tubing) System Drawing: OE183VS.1E (Dual Solenoid Valve Section With Optional Heater, ³∕8" Tubing) System Drawing: OE190VS (Single Solenoid Valve Section, ¼" Tubing) System Drawing: OE220VS.1E (Triple Solenoid Valve Section, ¼" and ³∕8" Tubing) IOM-181 | MODEL: ECOSYSTEM™ | REV: B 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 APPENDIX B: MAINTENANCE SCHEDULE Welker recommends keeping high-wear parts on hand and replacing these parts immediately when worn or damaged. Refer to the Installation, Operation, and Maintenance (IOM) Manual for each component for maintenance instructions. Table B1: ECOsystem™ Maintenance Schedule Action If applicable, confirm proper functioning of the heater. Open F-5 drain valve G to allow moisture to drain from the filter. Verify the pneumatic supply pressure. Rebuild the F-5 using a Welker® repair kit. • Replace the O-rings and filter cartridge. View the controller’s current alarms. Inspect the tubing, valves, and fittings on the system for leaks. Replace the controller battery. Maintain the flow switch. Maintain the regulator. Maintain the relief valve. Maintain the solenoid(s). 47 IOM-181 | MODEL: ECOSYSTEM™ | REV: B Every 12 Months Weekly 13839 West Bellfort Street, Sugar Land, TX 77498 As Necessary X X X X X X X X X X X welker.com Service Department: 281.491.2331 NOTES _______________________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________________ _______________________________________________________________________________________________________________________________________ 13839 West Bellfort Street Sugar Land, TX 77498 Phone: 281.491.2331 welker.com 48 IOM-181 | MODEL: ECOSYSTEM™ | REV: B 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331