1. No category

Installation, Operation, and
Maintenance Manual
Welker® Heated Gas Sample
with Enclosure
Model
HGS
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 the Welker equipment described above. Correct
operating and/or installation techniques, however, are the responsibility the end user. Welker reserves the
right to make changes to this and all products in order to improve performance and reliability.
This manual is intended to be used as a basic
installation and operations guide for the Welker
Heated Gas Sampler with enclosure. For complete
instructions please refer to the IOM Manuals for
each individual component, located in Appendix
A of this manual.
© Copyright 2010, Welker, Inc.
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
TABLE OF CONTENTS
1.
GENERAL
3
1.1
1.2
1.3
1.4
1.5
1.6
INTRODUCTION
DESCRIPTION OF PRODUCT
IMPORTANT INFORMATION
SPECIFICATIONS
SYSTEM COMPONENTS
PRINCIPAL OF OPERATION
3
3
4
4
5
5
2.
INSTALLATION & OPERATIONS
6
2.1 GENERAL
2.2 INSTALLATION
2.3 PURGING THE CYLINDER
2.4 SAMPLING
2.5 REMOVING AND REPLACING THE CYLINDER
6
6
8
8
9
3.
MAINTENANCE
10
3.1
3.2
GENERAL
READY THE SYSTEM FOR MAINTENANCE
10
10
APPENDIX A
11
ATTACHED IOM MANUALS
11
Welker®, Welker Jet®, and WelkerScope® are Registered Trademarks owned by Welker, Inc.
IOM-095
Heated Gas Sampler
Rev: A
Last updated: 3/26/2010
Page 2 of 12
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 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® Gas Sampler with Enclosure is
designed to provide the user with a quality sample
while utilizing a reduced-size format. It is equipped
with a compact and efficient Micro Purge Sampler
that provides Welker’s original fresh purge sample.
This system is enclosed in an insulated hot-pressed
glassfiber reinforced polyester enclosure, and
heated with a gas heater and thermostat to ensure
the equipment remains above dew point. This
product is designed to comply with the
recommendations of American Petroleum Institute
in the Manual of Petroleum Measurement
Standards, Chapter 14, Section 1.
IOM-095
Heated Gas Sampler
Rev: A
Last updated: 3/26/2010
Page 3 of 12
SPECIFICATIONS
1.3
IMPORTANT INFORMATION
This manual is to be used as a basic guide. Please read all the individual
component IOM manuals attached in Appendix A before following any set up,
installation, or maintenance instructions. If you have any questions, please
contact the Welker service department.
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. However, please note that the
specifications may vary depending on the customization of your product.
Table 1
Overall System Specifications
Products Sampled:
Gases
Materials of Construction:
316 stainless steel, aluminum, Viton®, and PTFE; others
available.
Maximum Allowable Operating
Pressure:
1,440 psi (99.28) bar
Sample Inlet/Outlet
Connections:
Vent to Flare Connection:
1
/4" NPT
1
/8" NPT
Temperature Range:
-20°F to 120°F (-28.9°C to 48°C)
MPS-2 Injection Volume:
.25cc
Single Cavity Cylinder Volume:
300 cc at 100% capacity; others available
Electrical Connections
(Heater/Thermostat):
12 VDC FOR START UP of CATALYTIC HEATER
PROCESS ONLY (time approximately 20 minutes)
Electrical Connections
Solenoid Valve:
12 VDC; others available
IOM-095
Heated Gas Sampler
Rev: A
Last updated: 3/26/2010
Page 4 of 12
SPECIFICATIONS
1.5
SYSTEM COMPONENTS
 Enclosure
 Welker MPS-2 Gas Sampling Pump
 Single Cavity Cylinder
 Instrument Supply Air Regulators (2)
 3-Way Versa Solenoid Valve 12 VCD
 4-Way Manifold Block with bracket
 Welker Check Valve
 Relief Valve
 Small Welker Valves NV-1
 Welker Filter
 Catalytic Heater with Thermostat
 Pressure and Temperature Gauges
 All associated fittings, tubing, etc.
1.6
PRINCIPLE OF OPERATION
1. The product will flow from a sample probe to the sample inlet on the
bottom the MPS-2 sampler.
2. Before sampling, a valve attached to the regulator can be opened, which
will purge the sample cylinder through the top port on the manifold block
and out the valve on the bottom of the cylinder using the fill-and-empty or
continuous-purge method of sampling.
3. Sample will flow through the sampler and into the regulator that will
regulate the supply gas at the pressure needed to supply the instruments
and heater, which heats the enclosure contents.
4. When the solenoid is energized, pipeline gas will flow through the sample
pump, regulator, solenoid, and the onto the piston inside the sampler,
which will then force the fresh representative sample collected in the
sampler through the check valve and into the sample cylinder. The sample
gas used to operate the sampler will then be vented off when the solenoid is
de-energized. (GAS needs to be vented outside of enclosure to not
extinguish catalytic reaction in heater.)
5. At the end the sample period, the representative sample collected in the
cylinder should be removed and transported to the lab for analysis and a
clean cylinder should be installed in the same position.
IOM-095
Heated Gas Sampler
Rev: A
Last updated: 3/26/2010
Page 5 of 12
INSTALLATION & OPERATIONS
2.
INSTALLATION 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.
The equipment will ship from the manufacturer, Welker, panel mounted and “hard tube”
connected and ready for mounting.
2.2
INSTALLATION INSTRUCTIONS
1.
Make sure that all valves on the unit are closed.
2.
Use the following instructions to mount the enclosure so it is level and above the
sample point (probe):
a. To be compliant with most company SOP the sampler needs to be mounted on the
pipeline to enclose and heat probe mounted on pipeline. Typical installation of
this unit is to use the mounting bracket and u-bolts provided to mount the
enclosure directly on the pipeline. (Continue reading before attempting to do
this).
b. On a typical gas pipeline for which the heated gas sampler has been designed,
downstream of the flow metering device should be three “taps” spaced six inches
apart. Typically, one “tap” is to collect the sample, one to measure the pipeline
temperature, and one to measure the pipeline pressure. Welker has designed the
HGS and enclosure so that it can be mounted on the pipeline whichever way best
suits your needs. You will have to figure out which way you want to install the
enclosure before mounting it to the pipeline.
c. At the bottom of the enclosure are three holes spaced apart so that the enclosure
can be mounted covering anywhere from one to all three of the taps.
Additionally, the enclosure door has easy access hinges, making the door
completely removable. This will allow you to face the enclosure in the direction
that is most suitable. Finally, the equipment is “divided” into two moveable
sections. It ships from the manufacturer with the heater section on the left side,
and the sampler section on the right, however this can be changed to the opposite
orientation in order to make room for your equipment, if necessary. First you will
need to decide where to mount the enclosure on the pipeline:
IOM-095
Heated Gas Sampler
Rev: A
Last updated: 3/26/2010
Page 6 of 12
INSTALLATION & OPERATIONS
 If mounting over only one “tap” and none of your equipment will be
inside the enclosure (i.e. temperature or pressure measuring device).
Align the enclosure over the correct “tap” and then proceed to Step 3.
 If mounting over two or three “taps”, you will need to situate the two
“sections” so that your equipment and a sample probe will all fit inside the
enclosure. If the sections need to be swapped:
1. Remove the heater by loosening the t-bolt and pulling the bracket
off the track.
2. Remove the heater assembly and set it aside.
3. Remove the conduit extension attached to the solenoid conduit and
set it aside.
4. Then loosen the t-bolts holding the sampler assembly so you can
slide it over to the other side of the enclosure. Be sure to turn the
conduit outlet the other direction also.
5. Tighten the sampler assembly into place and screw the conduit
extension in through the opposite hole it was on.
6. Replace the heater using the opposite side bracket and tighten the
t-bolt in place.
 Then, you will need to tube your equipment out of the enclosure (you can
use the hole opposite the conduit) to the end device (example totalizer).
 Once the enclosure and its contents have been arranged so that everything
fits with nothing constricting the door from closing, align the hole(s)
correctly above the corresponding “tap(s)”.
3.
Place the u-bolt underneath the pipeline and up through the correct holes on one end of
the bracket (see below for placement according to pipeline size). Tighten the u-bolt
with the two nuts provided. Repeat this procedure with the other u-bolt on the other
side of the bracket.( 2,3,4,6,8, inch pipelines)
4.
Install the Welker® sample probe of your choice through the appropriate enclosure
hole and into the “tap”. (See probe IOM for specific installation instructions).
IOM-095
Heated Gas Sampler
Rev: A
Last updated: 3/29/2010
Page 7 of 12
INSTALLATION & OPERATIONS
5.
6.
7.
8.
9.
10.
11.
12.
2.3
Use tubing to connect the sample point P1, on the probe installed on the pipeline, to
the product inlet connection P1 (1/4” NPT) located on the bottom of the MPS-2 Sample
Pump. (See diagram on page 5).
A vent connection on the top right side of the enclosure has been provided if you want
to vent the purge gas from the solenoid elsewhere.
Connect 12 VDC power from the rate controller to the solenoid through the conduit
outlet.
The regulator will reduce the pipeline supply pressure to the proper pressure necessary
to operate the solenoid safely. The regulator for this system will be factory set at 65
psi; see Norgren IOM attached for instructions on how to check the regulator to ensure
the settings did not change in transit.
Regulator is equipped with a relief valve to relieve pressure and protect the equipment
in case of a seal leak or other failure of the regulator. This relief valve will be factory
set at 75 psi.
There is an inline relief valve on the sample pump, which will need to be set at 100
PSI above pipeline pressure. Please see Welker IOM-056 for instructions on how to
reset the check valve and detailed instructions about the sampler.
Follow instructions on the attached IOM for the Bruest Catalytic Heater to start the
heater.
With all valves remaining closed, open the valve on the sample probe to allow product
to enter the system then proceed to purge instructions.
PURGING THE CYLINDER
1.
Open the purge valve that is attached to the regulator and behind the relief valve (also
attached to the regulator).
2.
For proper purging, please use the fill-and-empty method or continuous-purge method
found in the Gas Processors Association standard 2166-86 “Obtaining Natural Gas
Samples for Analysis by Gas Chromatography”.
2.4
SAMPLING
1.
Close the purge valve.
2.
Allow the pressure to bleed until the cylinder gauge reads zero.
3.
Close the bottom valve on the cylinder, and leave the top valve on the cylinder open.
4.
Activate the flow rate controller so the solenoid will start actuating.
5.
Allow the sampler to take .25cc of sample proportional to the rate of flow of the
sampler using your company guidelines for fill volume. If company policy is to fill
the cylinder to 100% capacity it will take approximately 1,200 actuations. The
cylinder gauge will reach pipeline pressure when it is full. If the cylinder continues to
collect sample once it is full, the pressure will increase.
IOM-095
Heated Gas Sampler
Rev: A
Last updated: 3/26/2010
Page 8 of 12
INSTALLATION & OPERATIONS
2.5
REMOVING AND REPLACING THE CYLINDER
1.
2.
3.
4.
Close the top valve on the cylinder.
Remove the cylinder from the bottom of the manifold block by unscrewing it.
Replace the cylinder with a clean one.
Purge the cylinder following instructions is Step 2.3, then begin the new sample
process.
IOM-095
Heated Gas Sampler
Rev: A
Last updated: 3/26/2010
Page 9 of 12
MAINTENANCE
3.
MAINTENANCE
3.1
GENERAL
Prior to maintenance or disassembly the unit, it is advisable to have a repair kit handy for
the system in case of unexpected wear or faulty seals.
We recommend that the unit have annual maintenance under normal operating
conditions. In the case of severe service, dirty conditions, excessive cycling usage, or
other unique applications that may subject the equipment to unpredictable
circumstances, a more frequent maintenance schedule may be appropriate.
3.2
READY THE SYSTEM FOR MAINTENANCE
1.
2.
3.
4.
Disconnect the electrical connections.
Depressurize the system, and close all valves.
Disconnect the tubing and remove individual components of the system for maintenance.
Open the filter top and replace the filter. Contact the sales department at Welker to order
a new filter.
5. Follow instructions in component IOM Manuals for complete maintenance procedures.
See Appendix A.
IOM-095
Heated Gas Sampler
Rev: A
Last updated: 3/26/2010
Page 10 of 12
APPENDIX A
ATTACHED IOM MANUALS:




Welker MPS-2 Sample Pump: Welker IOM-056
Welker NV-1 Valves: Welker IOM-105
Norgren R83 IOM
Bruest Catalytic Heater IOM
IOM-095
Heated Gas Sampler
Rev: A
Last updated: 3/26/2010
Page 11 of 12
13839 West Bellfort
Sugar Land, TX 77498-1671
Phone: (281) 491-2331
Fax: (281) 491-8344
Toll Free: (800) 776-7267
Web Page: www.welkereng.com
Installation, Operation, and Maintenance Manual
Welker® Gas Sampler
Model
MPS-2
The information in this manual has been carefully checked for accuracy and is intended to
be used as a guide to operations. 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 to improve performance and reliability.
13839 West Bellfort
Sugar Land, Texas 77498-1671
U.S.A.
Tel.: (800) 776-7267
Tel.: (281) 491-2331
Fax: (281) 491-8344
www.welkereng.com
© Copyright 2009, Welker Inc.
TABLE OF CONTENTS
1.
GENERAL ..................................................................................................................3
1.1
2.
3.
Introduction ........................................................................................................3
INSTALLATION INSTRUCTIONS .......................................................................3
2.1
Installing the Sampler........................................................................................3
2.2
Start-Up and Sequence of Operation ...............................................................4
MAINTENANCE INSTRUCTIONS .......................................................................5
3.1
General ................................................................................................................5
3.2
Disassembly ........................................................................................................5
3.3
Reassembly .........................................................................................................7
Appendix A – Drawings
Welker®, Welker Jet®, and WelkerScope® are Registered Trademarks owned by Welker.
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 IO&M Manual prior to installation and operation
of this equipment is required so that you have a full understanding of its application and
performance prior to commencement of use. If you have any questions, please call 1-800776-7267 or 1-281-491-2331 in the USA. The Welker MPS series sampler is a positive
displacement pump. It is designed to take a representative sample of a gas product, at
pipeline conditions, and pump it into a sample container. Used separately or as part of a
complete sampling system, the MPS will provide the user with an accurate and
representative sample of their product.
2.
Installation Instructions
2.1
Installing the Sampler
To place the unit into operation, the following procedures should be followed:
2.1.1
After unpacking the unit, check it over for compliance and any damages.
NOTE: The installation instructions are written from the position that the MPS is
part of a complete sampler system. If it is purchased as a sampler alone, the
system should be constructed in a fashion compatible to the following instructions.
Recommended System Components:
•
•
•
•
•
MPS series sampler
Sample probe (Welker Model GAL0020 or equal)
Instrument regulator with downstream relief valve and gauge
Electronic solenoid valve
Constant pressure sample cylinder
2.1.2
Before installing sampler onto the pipeline thread-o-let, be sure the probe is cut to
a length that will reach into the center one-third of the pipeline. The sampler
should be located in the least turbulent area available of the flowing stream, i.e.,
not in a header or blowdown stack and away from obstructions, elbows, or
partially closed valves.
2.1.3
Once the sampler is mounted, hook-up can be completed.
2.1.4
Tube from the “sample out” port on the sampler to the sample container. The
cylinder (container) should be located as close to the sampler as is possible. Use
small diameter stainless steel tubing (1/8” tubing is preferred).
NOTE: If a constant pressure cylinder is used, refer to those instructions for
complete details.
All connections must be checked carefully for leaks at full line pressure. No leaks
are acceptable within the complete sample system.
NOTE: When sealing fittings with PTFE tape, refer to the proper sealing
instructions for the tape used.
2.1.5
2.1.6
If your system is paced by an electronic signal from an outside source (i.e., turbine
meter, flow computer, etc.), make the appropriate electrical hook-ups at this time.
System is now ready for start-up.
2.2
Start-Up and Sequence of Operation
2.2.1
Open the probe valve on the GSS10MP18 sampler (if using the GAL0020 sampler
probe, the side-mounted needle valve will remain closed).
2.2.2
Set the instrument supply regulator at 65-70 psi.
2.2.3
To test the sample system, take the following steps:
•
Close the product inlet valve on the cylinder.
•
Actuate the sampler several times by energizing the solenoid valve.
•
Observe the gauge on the manifold. Build pressure to above line
pressure. Let the unit sit for several minutes and check for a drop
in pressure. If it does drop, check for leaks. If the sampler holds
pressure, the unit is ready to be placed in operation.
3.
Maintenance Instructions
3.1
General
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.
We recommend that the unit have bi-annual maintenance under normal
operating conditions. In the case of severe service, dirty conditions, excessive
cycling usage or other unique applications that may subject the equipment to
unpredictable circumstances, a more frequent maintenance schedule may be
appropriate.
Disassembly should be done in as clean an environment as possible. New seals
supplied in spare parts kits are not lubricated. They should be lightly coated with
lubrication grease (silicone grease or other) before they are installed into the
equipment. This helps in the installation of the seals while reducing the risk of
damage when positioning them on the parts. After the seals are installed, some
additional lubrication can be applied to shafts or cylinder inner diameters to allow
smooth transition of parts.
The following tools will be required:
3.2
•
12” adjustable wrench
•
6” adjustable wrench
•
8” channel lock pliers
•
hex wrench, sizes 5/32”, 3/16”, 1/4”, and 3/8”
•
Lubricant to apply to all O-ring seals when reassembling.
Disassembly
NOTE: The sampler must first be removed from the pipeline in order to perform
maintenance.
3.2.1
Close both probe valves.
3.2.2
Remove instrument regulator and solenoid valve.
3.2.3
Disconnect sample outlet tubing.
3.2.4
Remove sampler from probe (see Figure 3.1).
Figure 3.1
3.2.5
Unscrew cap (part #1) from motor housing (part #18).
3.2.6
Remove piston (part #17), spring (part #3), and spring retainer (part #16).
3.2.7
Inspect piston (part #17) for scratches or pits. The piston has a polished surface
and should be free from scratches or abrasions. Slightly lubricate before
reassembly.
3.2.8
Remove flow ring (part #5) and replace the two O-ring seals on each end (parts #4
and #14).
NOTE: Before installing new O-ring seals, be sure O-ring grooves are clean and
seals have been lubricated with silicone grease or an O-ring lubricant.
3.2.9
Remove relief cap (part #10) from body.
3.2.10 Remove poppet (part #11) and spring (part #8) by unscrewing spring adjuster (part
#9).
3.2.11 Inspect poppet for scratches and clean relief cap.
3.2.12 Replace O-ring (part #7).
3.2.13 Reassemble in reverse order. All seals and shafts should be lightly lubricated
before installation. Do not overtighten screwed connections. They are O-ring
sealed and need only be snug.
3.2.14 Reconnect instruments and cylinder.
3.2.15 Sampler is now ready to put into operation.
3.3
Reassembly
To reassemble the sampler, simply reverse the order of disassembly while paying
special attention to the following procedures:
3.3.1
O-rings and seals can be cut or destroyed during assembly. Please use caution
when assembling the sampler.
3.3.2
Lubricate the polished surfaces on the shafts and cylinders. Silicone grease is
recommended. Small amounts are sufficient.
3.3.3
Take extra care when reassembling the inner shaft, as it must travel through
several seals. Lubricate and rotate shaft while inserting, so as not to scratch the
shaft or damage the seals.
3.3.4
Snug the packing gland nuts after the sampler has been fully reassembled.
NOTE: Never tighten the nut unless it is leaking. DO NOT OVERTIGHTEN.
3.3.5
When the collection head assembly is being replaced, use caution with the internal
relief, making sure it is properly aligned while threading on the anvil/cylinder.
The anvil/cylinder must be attached securely to the inner shaft.
Welker® Instrument Valves
Model
NV-1 & NV-2
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 2008, Welker, Inc.
TABLE OF CONTENTS
1.
1.1
1.2
1.3
2.
2.1
2.2
2.3
3.
3.1
3.2
GENERAL
3
3
3
4
INTRODUCTION
SPECIFICATIONS
DIAGRAM
5
INSTALLATION & OPERATION
GENERAL
VALVE INSTALLATION
VALVE OPERATION
MAINTENANCE
5
5
5
6
GENERAL
VALVE MAINTENANCE
6
6
Welker®, Welker Jet®, and WelkerScope® are Registered Trademarks owned by Welker, Inc.
IOM-105
NV-1 & NV-2
Rev: A
Last updated: 9/8/2009
Page 2 of 8
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 which have been modified may have additional requirements and specifications that are not
listed in this manual.*
1.2
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.
General
Products
Gases/Liquids
Materials of
Construction
316 Stainless Steel, Aluminum, Viton®
and PTFE (others available)
Connections:
1
/4” NPT connections in MM, MF, or FF
configurations
Pressure Rating:
6,000 psi
Temperature
Rating:
-20° F to +400° F
Flow Coefficients:
CV for NV-1 is .182
CV for NV-2 is .290
IOM-105
NV-1 & NV-2
Rev: A
Last updated: 9/8/2009
Page 3 of 8
SPECIFICATIONS
1.3
DIAGRAM
IOM-105
NV-1 & NV-2
Rev: A
Last updated: 9/8/2009
Page 4 of 8
INSTALLATION & OPERATIONS
2.
INSTALLATION INSTRUCTIONS
2.1
GENERAL
After unpacking the unit, check it for compliance and for any damages which 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.
•
PTFE tape
•
Adjustable wrench
2.2
VALVE INSTALLATION
1. Tighten fittings.
Welker Instrument Valves (NV-1 & NV-2) are available with male or female fittings
on either opening of the body. Tighten the fittings on either the valve body or the
application, sealing the male fittings with PTFE tape.
2. Check for leaks.
2.3
VALVE OPERATION
1. Open and close the valve.
Turn the valve cap counterclockwise to open, and clockwise to close.
IOM-105
NV-1 & NV-2
Rev: A
Last updated: 9/8/2009
Page 5 of 8
MAINTENANCE
3.
MAINTENANCE INSTRUCTIONS
3.1
GENERAL
We recommend that the unit have a bi-annual maintenance under normal operating
conditions. In the case of severe service, dirty conditions, excessive cycling
usage, or other unique applications that may subject the equipment to
unpredictable circumstances, a more frequent maintenance schedule may be
appropriate.
Recommended Tools
It would be advisable to have the following tools available
for maintenance of the unit; however, tools used will vary
depending on model.
•
PTFE tape
•
Adjustable wrench
•
Seal kit
1
•
/8 hex wrench
•
Lubricant – anti-seize for threads
•
Lubricant -silicone for seals & O-rings
•
Pointed instrument for seat removal
3.2
VALVE MAINTENANCE
Refer to diagram on page 4.
1.
2.
3.
4.
Using an adjustable wrench, loosen and remove the valve from the application.
Using a 1/8 hex wrench, loosen the hex screw and remove the valve cap.
Using an adjustable wrench, loosen and remove the bonnet nut from the body.
Use a pointed instrument to carefully pick the seat and retaining ring out of the
valve body.
Take care not to scratch the threads or the seating surface inside the body.
Scratches on the surface or seals could cause the valve to leak.
5.
6.
Replace the seat and retaining ring.
Grasp the top of the valve stem, and turn the bonnet nut clockwise until the valve
stem comes out of the bottom of the bonnet nut.
IOM-105
NV-1 & NV-2
Rev: A
Last updated: 9/8/2009
Page 6 of 8
MAINTENANCE
3.2
VALVE MAINTENANCE (CONTINUED)
7.
Remove and replace the two small O-rings. Be careful not to overstretch, cut, tear,
or twist the O-rings when rolling them over the end of the stem and into place.
New seals supplied in spare parts kits are not lubricated. They should be
lightly coated with lubrication grease (silicone grease or other) before they
are installed into the equipment. This helps in the installation of the seals
while reducing the risk of damage when positioning them on the parts.
8.
9.
10.
11.
12.
13.
14.
Lightly grease the threads on the valve stem with anti-seize lubricant for threads.
Remove and replace the large O-ring on the bonnet nut. Be careful not to
overstretch, cut, tear, or twist the O-ring when rolling it over the threads and into
place.
Slide the top of the valve stem back up through the bottom of the bonnet nut.
Turn the bonnet nut counterclockwise, until it will no longer
turn, and the valve stem is all the way up. (See Figure 1).
Figure 1
Failure to perform this step completely will likely result in a
leak.
Thread the bonnet nut back into the valve body, and tighten
with an adjustable wrench.
Replace the valve cap onto the valve stem, making sure the
hex screw is aligned with the etched out portion of the valve
stem.
Replace the valve using the installation instructions in
Section 2.
IOM-105
NV-1 & NV-2
Rev: A
Last updated: 9/8/2009
Page 7 of 8
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
Additional Instructions - Bruest Catalytic Heater
To test regulators and thermostats on Heater: While testing the sampler, adjust the output on Norgren regulator on top of the gas sampler to 65 PSI. Output on Norgren street tee should be connected to the F7 filter. The F 7 should be connected to 912 fisher regulator on heater. Connect 0‐30 inches of water column gauge to the tee on inlet of the heater. Turn thermostat all the way counter clockwise to off position. Depress starter button on Heater. The gauge should move up to read 1 inch of water column. Turn thermostat all the way clockwise. You should hear a click sound while keeping the starter button depressed. The gauge should move up to read 3.5 ‐ 4 inches of water column. Turn thermostat back counter clockwise to off position gauge should move back to 1 inch of water column. Release starter button. Gauge should move up to about 5‐6 inches of water column. If gauge is reading higher than 3.5 inches of water column with starter button depressed adjust both regulators to have an output of 3.5 inches of water column. 13839 West Bellfort
Sugar Land, TX 77498-1671
Phone: (281) 491-2331
Fax: (281) 491-8344
Toll Free: (800) 776-7267
Web Page: www.welkereng.com