Welker Adjustable Probe IOM Instruction and Operating Manual

Welker® Adjustable Probe Model APM-4 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 above. Correct operating and/or installation techniques, however, are the responsibility of the end user. Welker reserves the right to make changes to this and all products in order to improve performance and reliability. 13839 West Bellfort Sugar Land, TX 77498-1671 (281) 491-2331 - Office (800) 776-7267 - USA Only (281) 491-8344 - Fax http://www.welkereng.com © Copyright 2009, Welker, Inc. TABLE OF CONTENTS 3 1. GENERAL 1.1 1.2 1.3 1.4 INTRODUCTION DESCRIPTION OF PRODUCT SPECIFICATIONS DIAGRAM 2. 2.1 2.2 2.3 2.4 2.5 3. 3.1 3 3 4 5 6 INSTALLATION & OPERATION GENERAL PREPARING THE PROBE FOR INSTALLATION INSTALLING THE PROBE HELPFUL HINTS RETRACTING THE PROBE MAINTENANCE 6 6 7 8 8 9 GENERAL 9 Welker®, Welker Jet®, and WelkerScope® are Registered Trademarks owned by Welker, Inc. IOM-009 AP3 Rev: C Last updated: 5/23/2011 Page 2 of 10 SPECIFICATIONS 1. GENERAL 1.1 INTRODUCTION We appreciate your business and your choice of Welker products. The installation, operation, and maintenance liability for this product becomes that of the purchaser at the time of receipt. Reading the applicable Installation, Operation, and Maintenance (IOM) Manual 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 1-800-776-7267 in the USA or 1-281-491-2331. Notes, Cautions, and Warnings Notes emphasize information or set it off from the surrounding text. Caution messages appear before procedures that, if not observed, could result in damage to equipment. Warnings are alerts to a specific procedure or practice that, if not followed correctly, could cause personal injury. *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 DESCRIPTION OF PRODUCT The Welker Adjustable Probe is designed for use in systems where it is desirable to insert or retract the probe while the pipeline remains pressurized. The preferred location for installation of the probe is in a straight section of inlet piping in which the product is well mixed, before the flowing stream is subjected to turns and impingements that can result in turbulent flow. IOM-109 APM-4 Rev: A Last updated: 5/23/2011 Page 3 of 10 SPECIFICATIONS 1.3 SPECIFICATIONS The specifications listed in this section are generalized for this equipment. Welker can modify the equipment according to your company’s needs. However, please note that *the specifications may vary depending on the customization of your product. Table 1 General Products Gases/Liquids Materials of Construction 316 Stainless Steel, Viton and PTFE (others available) Insertion Length 18” (457mm) Standard {others available in 1” (25.4mm) increments} Viscosity Range 0.009 cp to 2,000 cp @ 68° F (20°C) Pipeline Connection ½”, ¾” or 1” NPT for ¼” tubing ¾” or 1” NPT for ⅜” tubing 1” NPT for ½” tubing Sample Outlet Connection ¼” NPT for ¼” and ⅜” tubing ¼” or ½” NPT for ½” tubing Maximum Insertion/Retraction Pressure For ¼” tubing: 1,000psig (69barg) maximum For ⅜” tubing: 500psig (34barg) maximum For ½” tubing: 250psig (17barg) maximum Maximum Allowable Operating Pressure 1,440 psi @ -20° F to 100° F (99 bar @ -29° C to 38° C) Maximum Allowable Temperature 400° F @ 1,030 psi (204° C @ 71 bar) IOM-109 APM-4 Rev: A Last updated: 5/23/2011 Page 4 of 10 SPECIFICATIONS 1.4 DIAGRAM IOM-109 APM-4 Rev: A Last updated: 5/23/2011 Page 5 of 10 INSTALLATION & OPERATIONS 2. INSTALLATION & OPERATION INSTRUCTIONS 2.1 GENERAL After unpacking the unit, check it for compliance and for any damages that may have occurred during shipment. Claims for damages caused during shipping must be initiated by the receiver and directed to the shipping carrier. Welker is not responsible for any damages caused from mishandling by the shipping company. When sealing fittings with PTFE tape, refer to the proper sealing instructions for the tape used. Recommended Tools It would be advisable to have the following tools available for installation of the unit; however, tools used will vary depending on model.  Measuring tape  Allen wrench set  6" adjustable wrench  10" adjustable wrench  Permanent marker  Tubing cutters  Fine grit sandpaper  Small file 2.2 PREPARING THE PROBE FOR INSTALLATION 1. Determining the insertion length Before installing the unit, determine the length the insertion shaft will need to travel inside the pipeline. Measure from the top of the pipeline’s isolation valve to the center one-third of the pipeline. 2. Setting the insertion length on the shaft Once the insertion length of the shaft is determined, this length should be measured on the shaft itself (Refer to Figure 2 following steps 2a-2e on the next page.) IOM-109 APM-4 Rev: A Last updated: 5/23/2011 Page 6 of 10 INSTALLATION & OPERATIONS a. b. c. d. e. Fully retract the probe until the body is flush against the welded ferrule. Begin at the top of the body (and bottom of the lock down collar) and measure up on the shaft to the desired length. Mark this point on the shaft, as this is where you will lock the lock down collar into place. Move the lock down collar up on the shaft to the marked point. Use an Allen wrench to tighten the hex socket cap screws. The lock collar will clasp onto the shaft, locking the lock down collar into place. 3. Cutting off excess tubing from the shaft (optional) a. Measure up on the shaft approximately two inches from the lock collar. Mark this point on the shaft. b. Using tubing cutters, remove the excess tubing from the two-inch mark on the shaft. c. File and smooth the cut edge of the shaft. d. Replace the valve and male connector onto the shaft, and tighten the male connector lock collar to lock it into place. Make sure the valve is closed. Figure 1 2.3 INSTALLING THE PROBE 1. Make sure all valves on the unit are closed. 2. Retract the shaft from the base until the welded ferrule hits the body. 3. With the pipeline isolation valve closed, install the unit onto the pipeline isolation valve. 4. Slowly open the pipeline isolation valve until it is completely open, and push the shaft down into the pipeline. When pushing the shaft down into the pipeline, push straight down and do not allow the shaft to bend. As pipeline pressure will be pushing up on the shaft, you will have to firmly push down on the unit in order to insert the shaft. Maximum Allowable Insertion/Retraction Pressure is located on page 4 of this manual. Do not insert the probe at pressures higher than the maximum. IOM-109 APM-4 Rev: A Last updated: 5/23/2011 Page 7 of 10 INSTALLATION & OPERATIONS 5. Tighten the hex head machine screws to bolt the lock down collar onto the base, holding the shaft in the pipeline. Do not let go of the unit until the lock down collar is securely tightened. 6. Connect the product out valve to the end user product or apparatus. 7. Open the valve. 2.4 HELPFUL HINTS 1. Avoid rough handling of the unit and bending of the shaft. The shaft has a polished surface that travels through seals. 2. Operate the unit slowly and smoothly while inserting and retracting. 3. The entire unit should be treated with care. 2.5 RETRACTING THE PROBE Pipeline pressure will be forcing the shaft out of the pipeline. Failure to push down on the unit while loosening the lock down collar assembly could cause a rapid retraction of the probe from pipeline, possibly resulting in injury. Maximum Allowable Insertion/Retraction Pressure is located on page 4 of this manual. Do not remove the probe at pressures higher than the maximum. 1. Close the two valves on the probe. 2. Disconnect the end user product or apparatus. 3. Firmly push down on the unit while slowly loosening lock down collar from the base. 4. Make sure the probe has completely retracted from the pipeline by pulling up on the shaft until it stops. Pipeline pressure will assist you with this process. The most common cause for repairs to an adjustable probe is due to the pipeline isolation valve closing on the probe while the probe is still inserted into the pipeline. Please avoid this practice. 5. Close the pipeline isolation valve. 6. Loosen and remove the unit from the pipeline isolation valve. 7. The unit is now ready for maintenance or to be moved to another location. IOM-109 APM-4 Rev: A Last updated: 5/23/2011 Page 8 of 10 MAINTENANCE 3. MAINTENANCE 3.1 GENERAL Maintenance should not be necessary unless a leak occurs due to improper or excessive use of the unit. Prior to maintenance or disassembly of the unit, it is advisable to have a repair kit handy for the system in case of encountering unexpected wear or faulty seals. Recommended Tools It would be advisable to have the following tools available for installation of the unit. However, tools used will vary depending on cylinder model and connectors used.         6" adjustable wrench 10" adjustable wrench Tubing cutters 1 /4" stainless steel ferrule set fine grit sandpaper small file O-ring kit Stainless steel replacement tubing Refer to diagram on page 5. 1. Loosen and remove the valve from the top of the shaft. 2. Loosen the lock down collar from the shaft. 3. Cut and remove the shaft tubing from the unit’s components. The tubing can be discarded. 4. Replace the O-Rings, Wiper, Back Ups, Bearing, and Snap Ring inside the base. 5. Replace the O-Ring inside of the male connector. 6. Replace the tubing and stainless steel ferrule set. 7. Proceed to installation instructions on page 6 to reinstall the probe. IOM-109 APM-4 Rev: A Last updated: 5/23/2011 Page 9 of 10 13839 West Bellfort, Sugar Land, Texas 77498-1671 Phone: (281) 491-2331 Fax: (281) 491-8344 Toll Free: (800) 776-7267 Web Page: www.welkereng.com