RETRACTION

Installation,
Operation
&
Maintenance
Manual

Copyright 2004 Welker Engineering Company

 Welker® Refined Products
Sampling System
Model
RVPSYSECO

(Welker® Drawing No. LS1010.5.2 thru LS1010.5.6 Rev. A &

EL797.2 thru EL797.6 Rev. -)

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 Engineering Company reserves the right to make changes
to this and all products to improve performance and reliability.

Welker Engineering Company

P.O. Box 138
Sugar Land, Texas 77487-0138
U.S.A.
Tel.: (800) 776-7267
Tel.: (281) 491-2331
Fax: (281) 491-8344
www.welkereng.com

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 Table of Contents

1. GENERAL.............................................................................................................................. 4
1.1 Introduction..................................................................................................................... 4
1.2 System Components (Part # is included in parenthesis)................................................. 4
2. PRINCIPLE OF OPERATION............................................................................................... 5
2.1 Atmospheric Containers.................................................................................................. 5
3. INSTALLATOIN ................................................................................................................... 6
3.1 Installation....................................................................................................................... 6
4. START UP.............................................................................................................................. 7
5. ATMOSHPERIC CONTAINERS ...................................................................................... 7
5.1 Atmospheric Container Sampling Sequence .................................................................. 7
5.2 Atmospheric Container Removal.................................................................................... 7
6. P.L.C. SEQUENCE OF OPERATIONS ............................................................................ 8
7. Maintenance................................................................................................................................ 9
7.1 CAUTION....................................................................................................................... 9
7.2 Trouble Shooting ............................................................................................................ 9
7.3 Parts Replacement........................................................................................................... 9
7.4 Pump Assembly and Disassembly................................................................................ 10
7.5 Spare Parts .................................................................................................................... 11
Appendix A – Drawings
Appendix B – Manufacturer’s Data Sheets

Welker® and WelkerScope® are Registered Trademarks owned by Welker Engineering

Company.

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1. GENERAL

1.1 Introduction

We appreciate your business and your choice of Welker Engineering Company 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 1-800-776-7267 or 281-491-2331 in the USA. For help in

South American please call 011-57-1-533-7736.

The purpose of the sampling system is to allow a representative sample of product, from

flowing pipeline, to be drawn from the pipeline and transferred into an Atmospheric

Container for analysis. The product shall be circulated through a “hot loop”, will be

sampled out of this “hot loop” line by the SSO-9, and will be pumped to a selected

container. There shall always be a purge cycle prior to all collection cycles.

The system shall be controlled by the customer’s P.L.C.

1.2 System Components (Part # is included in parenthesis)

SSO-9FV (50cc) Liquid Sample Pump (SSO9FVRVP)

4-Way Skinner Pilot Solenoid (ESVSK42AX31)

1 gallon Aluminum Container caps and Cap Adapters

Replacement Can (MM515OO) and Adapter (MM516OA & ME342OO)

Humphrey Manual Actuating Valves (VL01SOB)

Whitey Air Actuated, Spring Return 3-Way Ball Valves (VL24OO)

3-Way Skinner Solenoids (ESVSK32SX31)

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 System Lubricator/Oiler (ME150OO)

Needle Valves and Associated Piping, Fittings, etc.

CV-1 Check Valve to Sump/downstream Dump (CV1BF04M04X)

Nupro Filter (to filter P/L product in route to pump) (MF567OX)

Explosion Proof Terminal Box and Terminal Block

Panel Including Drip Pan

PP-2 Pitot Probe for Sample Hot Loop

NOTE: The above equipment will ship from the manufacturer, i.e. Welker Engineering,

panel mounted and “hard tube” connected and ready for mounting to the customer wall.

The SSO-9 sample pumps require 40-90 psig of air or nitrogen supply for operation.

The customer’s pneumatic supply shall be connected to the panel, “air inlet”.

2. PRINCIPLE OF OPERATION

2.1 Atmospheric Containers

2.1.1 The customer’s P.L.C. will start the sampling operation when the batch is to be sampled

after purging of system has taken place.

2.1.2 The system is provided with (1) Welker SSO-9 pump that will allow the customer to

sample the pipeline product.

2.1.3 The SSO-9 pump and sample containers will allow the customer to sample a single

pipeline or product.

2.1.4 The P.L.C. will activate the 3-way solenoid to the appropriate container which will in

turn actuate the associated ball valve thus allowing a sample to be pumped into the

selected container.

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2.1.5 On a single, proportional-to-flow or time-based, from the P.L.C., the (1) SSO-9 4-way

solenoid shall activate to allow instrument supply (90 psig) to the inlet side of the SSO-9

pump to displace said sample. The SSO-9 pump shall be activated, proportional-to-flow

or time-based, to obtain a representative sample of a batch.

2.1.6 At the end of the batch or allotted time, the representative sample collected in the selected

container or containers shall be removed and transported to the lab for analysis, and a

clean container shall be installed in the same position.

3. INSTALLATOIN

3.1 Installation

3.1.1 The P1 line from the PP-2 sample probe shall be connected to the SSO-9 inlet tee marked

sample inlet. The P2 line from the PP-2 sample probe shall be connected to the remaining

open NPT on the inlet tee. Both lines should be ¼” OD 316 S.S. tubing.

3.1.2 The Panel Instrument Air Supply inlet port shall be connected to the customer’s supply

system.

3.1.3 The SSO-9 outlet port located on the air actuated ball valve shall be connected to the inlet

fitting on the sample container panel using ¼” OD 316 S. S. tubing.

3.1.4 The sample container panel instrument air supply inlet port shall be connected to the

customer’s supply system (125 PSI max) ¼” OD 316 S. S. tubing.

3.1.5 The sample container panel return to sump on pipeline shall be connected downstream of

sample point in a low pressure area or to Customer sump using ¼” OD 316 S. S. tubing.

3.1.6 The SSO-9 solenoid and the container selection solenoids shall be connected to the

customer’s P.L.C. by way of the terminal box.

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4. START UP
4.1.1 After installation of the R.V.P. System, the SSO-9 pump can be purged of any trapped air

by pressurizing the “hot loop” line and loosening the 1/8” NPT plug (located on the front

of the SSO-9 lower flange) slightly just enough to allow product to bleed by.

4.1.2 Actuate the SSO-9 twice to displace any air that might be trapped in the lower pump

connection fitting, then quickly re-tighten pipe plug. Continue with sampling sequence to

purge the rest of the system.

5. ATMOSHPERIC CONTAINERS

5.1 Atmospheric Container Sampling Sequence

5.1.1 The P.L.C. will activate the proper solenoid to sample into the selected

container. This will switch the associated 3-way ball valve to allow the sample to be

pumped from the circulation loop into the selected container for storage, removal, and

transportation to the lab.

5.1.2 The P.L.C. can purge the system by actuating the SSO-9 pump 4-way solenoid, while at

the same time not activating any of the container selection solenoids. This will allow all

samples that are being taken, to be pumped through the system, and through the check

valve to the pump or down stream piping or sump.

5.1.3 The P.L.C. will de-activate the purge cycle by activating one of the container selection

solenoids thus allowing the samples being taken by the SSO-9 pump to be collected in

the chosen sample container.

5.1.4 The SSO-9 solenoid will be paced by the P.L.C. to cause a sample to be taken

from circulation loop, by the SSO-9, and pumped into the selected containers.

5.2 Atmospheric Container Removal

5.2.1 Caps are attached to the sample bottle. A tube fills the sample container from bottom to

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 top.

5.2.2 In each cap, there is a vent connection that is piped to the vent manifold.

5.2.3 The inlet valve is attached to the vacuum breaker valve (brass push button valve) to

remove the full sample container.

5.2.4 After the sample period is over and the container is filled, prior to removing the container

cap, press the button on the vacuum breaker valve to release the product in the tubing.

5.2.5 Remove the cap and container

5.2.6 Tag container and put a transportation cap on it for storage and/or transportation.

6. P.L.C. SEQUENCE OF OPERATIONS

The operator will input into the P.L.C. the batch size and the volume of the sample

container, or the batch time and the number of samples to be taken per minute. The

operator will also select the containers in which to collect the sample.

6.1 The P.L.C. signals the 4-way solenoid which will in turn activate the SSO-9 pump “X”

times to purge system lines to drain sump or pipeline.

“X” = The number of strokes required to purge the system.

6.2 The P.L.C. de-activates the purge cycle, when the purge cycle is complete, by activating

one of the container selection solenoids.

6.3 The P.L.C. switches the SSO-9 4-way solenoid to switch the associated 3-way air

actuated ball valve to allow product to enter the SSO-9 at the same time air pressure is

applied to the power piston to draw a sample into the SSO-9 pump. The air on the back

side of power piston is exhausted through the 4-way solenoid.

6.4 The P.L.C. switches the SSO-9 4-way solenoid to switch the 3-way air-actuated ball

valve to transfer the sample from the SSO-9 to the collection container. Air is applied at

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 the same time to back side of the power piston to pump the sample into the collection

cylinder. The air on the fill side of the power piston is exhausted through the 4-way

solenoid.

6.5 Steps 3. and 4. are repeated until desired volume of sample has been collected in the

selected container.

6.6 The P.L.C. will de-activate the selected container solenoid when desired volume is

collected.

7. Maintenance

7.1 CAUTION

7.1.1 CAUTION: DO NO DISASSEMBLE THE 3-WAY BALL VALVE FROM THE

VALVE ACTUATOR. IMPROPER REASSEMBLY WILL AFFECT THE
SAMPLING PROCESS BECAUSE OF IMPROPER VALVE ORIENTATION.

7.2 Trouble Shooting

7.2.1 If sample pump is not taking a sample, check for the following:

1. Pipeline is open to sample pump.

2. Controller is functioning.
3. Signal from meter is being received by controller.
4. Solenoid is operating.
5. Pneumatic supply is not off.
6. Pneumatic supply is supplied to sample pump.

7.2.2 After all above has been satisfied, maintenance on the pump will have to be performed.

7.2.3 If help is required on a problem with the operation of the sampling pump, please contact
the Service Department at Welker Engineering Company at 1-800-776-7267 or 011-57-1-
533-7736 for Welker South America.

7.3 Parts Replacement

7.3.1 Refer to attached parts list for ordering

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7.4 Pump Assembly and Disassembly

7.4.1 Before removing sampling pump from its installation, tag tubing and identify how it is
tubed, paying special attention to the orientation of the 3-way ball valve. This is
important to assure proper re-installation of the unit.

NOTE: Refer to the attached cross-sectional drawing of the pump.

7.4.1.1 Make sure all product has been purged from the sample pump.

7.4.1.2 Make sure pressure has been relieved from both the power and the sample

cylinders.

7.4.1.3 Remove all tubing from the sample pump.

7.4.1.4 Remove tie bolts from both ends of the sample pump.

7.4.1.5 Remove end caps.

7.4.1.6 Carefully slide the cylinders off the pistons.

7.4.1.7 Remove both pistons from the drive shaft by holding back up with wrench on

flats provided on shaft. Slide drive shaft out of cylinder base.

7.4.1.8 Closely examine the honed surface in both cylinders and the surface finish on

the drive shaft.

7.4.1.9 Remove all the old seals, making note of orientation.

7.4.1.10 Wipe clean all the o-ring grooves and sealing surfaces.

7.4.1.11 Replace all seals on the end caps, pistons, and cylinder base in the same

orientation as when removed in paragraph 12 above.

NOTE: Coat all seals lightly with an o-ring lubricant or silicone grease.

7.4.1.12 Install sample piston (small) onto the drive shaft, tighten piston holding screw

while holding back up with wrench, using flats provided on shaft.

7.4.1.13 Insert piston into cylinder, drive shaft end first. Be sure not to damage

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 cylinder bore with drive shaft. It must be installed this way so that the bal-seal

“U” will be facing the fluid.

7.4.1.14 Slide drive shaft through the cylinder base and slide cylinder onto the cylinder

base seal.

7.4.1.15 Replace power piston (large) onto the drive shaft. Push power piston against

cylinder base, holding sample cylinder to keep sample cylinder on cylinder

base. Tighten power piston on shaft, holding back up by using second Allen

wrench in sample piston holding screw.

7.4.1.16 Replace the end cap.

7.4.1.17 Install the tie bolts and tighten nuts to 6 ft. lbs.

7.4.1.18 Slide power cylinder onto piston being careful not to damage u-cups with “U”

facing towards air/gas.

7.4.1.19 Cylinder must be pushed down until it seals on cylinder base.

7.4.1.20 Replace end cap on power cylinder.

7.4.1.21 Install tie bolts and tighten nuts to 6 ft. lbs.

7.4.1.22 Re-connect all instrument tubing.

7.4.1.23 Re-install unit following the installation making special note of orientation of

3-way ball valve.

7.5 Spare Parts

Recommended Spare Parts For

SSO-9FVRVP Refined Products Sample Pump

DESCRIPTION QTY. PART # SEAL KIT

Back Up Ring, Spiral 6 BU208SP *
Back Up Ring, Spiral 2 BU210SP *
U-Cup 2 MS044OO *
Variseal 1 MS118OO *

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 O-Ring 2 VO70009 *
O-Ring 2 VO90014 *
O-Ring 1 VO70208 *
O-Ring 3 VO70210 *
O-Ring 2 VO70231 *
Retaining Ring 1 RR038OX
3-Way Air Actuated Ball Valve w/ CO9 Seals 1 VL439DACO9

For 1 year spares and maintenance, 2 seal kits and 1 repair kit are recommended.
For 2 year spares and maintenance, 4 seal kits and 1 repair kit are recommended.

Seal Kit # OKAD243BM

Repair Kit # RKAD243BM
DWG # AD243BM Rev. D

• The seal kit includes, but is not limited to, those parts designated by asterisks.
• Quantities listed are the amount installed on the product.
• We recommend that the unit have bi-annual maintenance under normal operating
conditions. In the case of severe or dirty service, excessive cycling usage or other unique
applications that may subject the equipment to unpredictable circumstances, a more
frequent maintenance schedule may be appropriate.

Appendix A – Drawings

Appendix B – Manufacturer’s Data Sheets

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