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. D, 05/04/2017 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 18 3. TOUCH SCREEN CONTROLLER 20 3.1 Understanding the Display 20 3.2 Navigating the Monitor Menus 23 3.3 Navigating the Setup Menus 31 4. MAINTENANCE 52 4.1 Before You Begin 52 4.2 Maintenance 52 APPENDICES 53 A: Referenced or Attached Documents 53 B: Maintenance Schedule 54 Copyright © 2017 Welker, Inc. All rights reserved. Welker®, W Welker®, W logo, WelkerScope®, Welker Jet®, and OdorEyes® are registered trademarks of Welker, Inc. 2 IOM-181 | MODEL: ECOSYSTEM™ | REV: D 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: D 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: D 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 Flag Tracker Level Indicator 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: D 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: D 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: D 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: D 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: D 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: D 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: D 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: D 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: D 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: D 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 Sections With ³∕8" Tubing) 15 IOM-181 | MODEL: ECOSYSTEM™ | REV: D 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: D 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. 10. If the ECOsystem™ is not equipped with the optional flag tracker level indicator, installation is now complete; proceed to Section 2.3, Start-Up Procedures. If the ECOsystem™ is equipped with the optional flag tracker level indicator, continue to step 11. Flag Tracker Level Indicator (Optional) The float and gasket must be installed to the flag tracker level indicator prior to filling the odorant supply tank. The float and gasket are packaged separately for shipment. 11. 12. Remove the bottom drain flange from the base of the level indicator. Install the float to the spring on the bottom drain flange. The top of the float should point up. The top of the float is marked to ensure proper orientation. The spring attached to the bottom drain flange cushions the float when the odorant supply tank is empty. 13. 14. 17 Replace the shipping gasket with the provided gasket. Install the bottom drain flange with float to the level indicator. IOM-181 | MODEL: ECOSYSTEM™ | REV: D 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 2.3 Start-Up Procedures Odorant Supply Tank 1. 2. Open emergency bypass valves B1 and B2 (Figure 3, Figure 4, Figure 5, Figure 6, Figure 7, Figure 8, or 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, Figure 4, Figure 5, Figure 6, Figure 7, Figure 8, or 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, Figure 4, Figure 5, Figure 6, Figure 7, Figure 8, or 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. 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. 18 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. IOM-181 | MODEL: ECOSYSTEM™ | REV: D 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 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. 19 From the controller, verify the correct operation of the solenoid and flow switch. From the Home screen, select Monitor (Figure 15). From the Monitor menu, select System I/O (Figure 19). As the controller opens the solenoid, verify that Flow Switch and Main Sol darken simultaneously. As the controller closes the solenoid, verify that Flow Switch and Main Sol clear simultaneously. Once the correct operation of the solenoid and flow switch has been confirmed, the ECOsystem™ is operational. IOM-181 | MODEL: ECOSYSTEM™ | REV: D 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 Home screen is the top screen in the menu tree (Figure 12). Figure 12: Home Screen From the Home screen, the user can access three (3) types of screens: Menu-from this type of screen, the user can access submenus. • Informational-from this type of screen, the user can monitor the odorizer and view current operating conditions. These • screens have a blue background. Setup-from this type of screen, numeric and/or text values that affect the setup of the odorizer can be changed. These • screens have a red background. 20 IOM-181 | MODEL: ECOSYSTEM™ | REV: D 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 Navigating the Display Figure 13: Toolbar and Function Keys The toolbar appears on every screen except the Home screen. If nothing on the screen is pressed for a certain amount of time, the sleep function will cause the backlight on the screen to turn off. To wake up the controller, press anywhere on the screen or press one of the function keys. Viewing the Current Alarms From any screen, press the F2 key to go to the Current Alarms screen (Figure 14). Figure 14: Current Alarms Screen 21 IOM-181 | MODEL: ECOSYSTEM™ | REV: D 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 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 22 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: D 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 3.2 Navigating the Monitor Menus Through the Monitor menus, the user can access the Rates & Totals, Solenoid Stats, Tank Level, System I/O, Local Audit Trail, and Local Alarms Log to view current information for the odorizer. Monitor screens, which have a blue background, are informational screens: no values can be changed from these screens. Figure 15: Monitor Menu Submenus 23 IOM-181 | MODEL: ECOSYSTEM™ | REV: D 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 Rates & Totals The Rates & Totals submenu provides the user with an overview of system performance. Figure 16: Monitor Menu – Rates & Totals 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. 24 IOM-181 | MODEL: ECOSYSTEM™ | REV: D 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 Solenoid Stats Figure 17: Monitor Menu – Solenoid Stats 25 IOM-181 | MODEL: ECOSYSTEM™ | REV: D 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 Odorant Tank Level Figure 18: Monitor Menu – Tank Level 26 IOM-181 | MODEL: ECOSYSTEM™ | REV: D 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 System I/O The System 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 19: Monitor Menu – System I/O, 1 of 2 27 IOM-181 | MODEL: ECOSYSTEM™ | REV: D 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 Figure 20: Monitor Menu – System I/O, 2 of 2 28 IOM-181 | MODEL: ECOSYSTEM™ | REV: D 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 Local Audit Trail From the Local Audit Trail submenu, the user can access the audit trail records stored on internal memory. Up to 600 audit trail records can be stored and viewed. If SD Card Data Logging is enabled, the audit trail records will also be stored on the installed micro SD card. The micro SD card is equipped with 8 GB of storage. Figure 21: Monitor Menu – Local Audit Trail 29 IOM-181 | MODEL: ECOSYSTEM™ | REV: D 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 Local Alarms Log From the Local Alarms Log submenu, the user can access the alarms log stored on internal memory. Up to 428 logged alarms can be stored and viewed. If SD Card Data Logging is enabled, the logged alarms will also be stored on the installed micro SD card. The micro SD card is equipped with 8 GB of storage. Figure 22: Monitor Menu – Local Alarms Log 30 IOM-181 | MODEL: ECOSYSTEM™ | REV: D 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 3.3 Navigating the Setup Menus Through the Setup menu, the user can access the Controller Setup, Odorant Tank, Gas Flow Signal, Modbus Setup, Auto Scroll Setup, and Logging Setup 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 submenus will alter how the system operates. Figure 23: Setup Menu Submenus 31 IOM-181 | MODEL: ECOSYSTEM™ | REV: D 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, press on the value to be changed. A keypad will appear on the screen. Type the new 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 arrow keys 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 the Home button to discard the changes and return to the Home screen. 32 IOM-181 | MODEL: ECOSYSTEM™ | REV: D 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: Setup Menu – Controller Setup 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. 33 IOM-181 | MODEL: ECOSYSTEM™ | REV: D 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 Analog Output Setup Figure 25: Controller Setup – Analog Output Setup 34 IOM-181 | MODEL: ECOSYSTEM™ | REV: D 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 Solenoid Setup Figure 26: Controller Setup – Solenoid Setup 35 IOM-181 | MODEL: ECOSYSTEM™ | REV: D 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 Odorant Tank Setup Through the Odorant Tank Setup submenus, the user can input information for the odorant tank and temperature transmitter. Figure 27: Setup Menu – Odorant Tank 36 IOM-181 | MODEL: ECOSYSTEM™ | REV: D 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 Tank Level Setup Figure 28: Odorant Tank – 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. 37 IOM-181 | MODEL: ECOSYSTEM™ | REV: D 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 Tank Volume Setup Figure 29: Odorant Tank – Tank Volume Setup 38 IOM-181 | MODEL: ECOSYSTEM™ | REV: D 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 Figure 30: Tank Volume Setup – Strapping Tables If the odorant tank is horizontal, the strapping points will be calculated and entered at the factory. 39 IOM-181 | MODEL: ECOSYSTEM™ | REV: D 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 RTD Setup Figure 31: Odorant Tank – 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. 40 IOM-181 | MODEL: ECOSYSTEM™ | REV: D 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 Odorant Type Setup Figure 32: Odorant Tank – 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. 41 IOM-181 | MODEL: ECOSYSTEM™ | REV: D 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 33: Setup Menu – Gas Flow Signal 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/Modbus Cutoff must also be set (Figure 34). 42 IOM-181 | MODEL: ECOSYSTEM™ | REV: D 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 Fail/Fixed Mode Setup Figure 34: Gas Flow Signal – Fail/Fixed Mode Setup Setting the Fail Mode to Constant Rate will allow odorization to continue at the specified rate. Setting the Fail Mode to Shutdown will halt odorization until the alarm is cleared. If the gas flow value does not change during the Pulse/Modbus 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. 43 IOM-181 | MODEL: ECOSYSTEM™ | REV: D 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 Modbus Setup Figure 35: Setup Menu – Modbus Setup 44 IOM-181 | MODEL: ECOSYSTEM™ | REV: D 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 Port MJ1/MJ2 Setup Figure 36: Modbus Setup – Port MJ1/MJ2 Setup 45 IOM-181 | MODEL: ECOSYSTEM™ | REV: D 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 MJ1/MJ2 Modbus Setup Figure 37: Port MJ1/MJ2 Setup – MJ1/MJ2 Modbus Setup 46 IOM-181 | MODEL: ECOSYSTEM™ | REV: D 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 Ethernet Setup Figure 38: Modbus Setup – Ethernet Setup 47 IOM-181 | MODEL: ECOSYSTEM™ | REV: D 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 Auto Scroll Setup Figure 39: Setup Menu – Auto Scroll Setup 48 IOM-181 | MODEL: ECOSYSTEM™ | REV: D 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 Figure 40: Auto Scroll Pre-Set Screens Logging Setup Through the Logging Setup submenus, the user can set up and reset the data logs stored locally. If a micro SD card is installed, data will automatically be logged to the installed card when Data Logging is enabled. 49 IOM-181 | MODEL: ECOSYSTEM™ | REV: D 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 Figure 41: Setup Menu – Logging Setup If the micro SD card needs to be removed, first disable Data Logging. Failure to disable Data Logging prior to removing the micro SD card will trigger the SD Card Error alarm. To continue data logging, insert a new micro SD card, and then enable Data Logging through the Logging Setup submenu (Figure 41). 50 IOM-181 | MODEL: ECOSYSTEM™ | REV: D 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331 SD Card Diagnostics Figure 42: Logging Setup – SD Card Diagnostics SD Card Access Figure 43: Logging Setup – SD Card Access 51 IOM-181 | MODEL: ECOSYSTEM™ | REV: D 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. 52 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: D 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-105: Welker NV-1 and NV-2 Instrument Valves IOM-169: Welker F-5 Filter Dryer Other Installation, Operation, and Maintenance (IOM) Manuals suggested for use with this unit: • • • • • • • • • • • • • • • • • • • • • • • • • • ABB Inc. K-TEK Products 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 WX Series (Welker IOM-V030) Emerson Process Management Regulator Technologies, Inc. Fisher™ 1301 Series High-Pressure Regulators Types 1301F and 1301G (Welker IOM-V107) Gems Sensors Inc. 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, LLC XL4 OCS Modules (Welker IOM-V369) Horner APG, LLC XLe/XLt OCS Modules (Welker IOM-V224) Inline Industries, Inc. 201F Ball Valve (Welker IOM-V222) INTERTEC Instrumentation Ltd. CP MULTITHERM C Electric Heater (Welker IOM-V104) INTERTEC Instrumentation Ltd. TS Thermostat (Welker IOM-V105) MTS Systems 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) Quest-Tec Solutions Magne-Trac™ Level Indicators (Welker IOM-V367) Saginaw Control & Engineering EL Enclosure SCE-30EL3012LP (Welker IOM-V265) Solutions With Innovation L505 Visual Level Indicator 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 Instrument Corporation Bourdon Tube Pressure Gauges Type 232.53 and Type 233.53 (Welker IOM-V171) Welker drawings and schematics suggested for use with this unit: • • • • • • • 53 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: D 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). 54 IOM-181 | MODEL: ECOSYSTEM™ | REV: D 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 55 IOM-181 | MODEL: ECOSYSTEM™ | REV: D 13839 West Bellfort Street, Sugar Land, TX 77498 welker.com Service Department: 281.491.2331