Welker AP-3, AP-3F Installation, Operation And Maintenance Manual

INSTALLATION, OPERATION, ANDMAINTENANCEMANUAL

WELKER ADJUSTABLEPROBE

MODELS

AP-3 AP-3F 

DRAWING NUMBERS

AD126BU AD126CO AD126DR AD126EH 

MANUALNUMBER

IOM-009



REVISION

Rev. D, 10/19/2018

TABLEOF CONTENTS

 SAFETY 3

1. PRODUCT INFORMATION 4

1.1 Introduction 4

1.2 Product Description 4

1.3 Specifications 5

1.4 Equipment Diagrams 6

  

2. INSTALLATION & OPERATION 8

2.1 Before You Begin 8

2.2 Preparing the AP-3 for Installation 8

2.3 Installing the AP-3 10

2.4 Retracting the AP-3 11

  

3. MAINTENANCE 12

3.1 Before You Begin 12

3.2 Maintenance 12

  

 APPENDIX 15

 A: Referenced or Attached Documents 15

IOM-009 MODELS: AP-3 and A P-3F REV: D 13839 West Bellfort St reet, Sugar L and, TX 77498 welker. com Servic e Departm ent 281.491.2331

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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 a nd operation g uide for the Welker Adjustable Probes, AP-3 and AP-3F. For com prehensive instructions, please refer to the IOM Manua ls for each individual component. A list of relevant comp onent IOM Manua ls is provided in Appendix A of this manual.

The informa tion in this manu al has been carefully chec ked for accurac y and is intended to be used a s a guide for the installation, operation, and maintenance o f the Welker equipment described in this manual. Correct installation and operation, however, are the respo nsibility of the en d user. Welker reserves the right to ma ke cha nges to this man ual and a ll products in order to improve p erformance 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 Adjustable Probe is of a mechanical 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 Adjustable Probe, please contact a Welker representative immediately.

Phone: 281.491.2331 Address: 13839 West Bellfort Street

Sugar Land, TX 77498

IOM-009 MODELS: AP-3 and A P-3F REV: D 13839 West Bellfort St reet, Sugar L and, TX 77498 welker. com Servic e Departm ent 281.491.2331

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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 p roced ures have been written for use with standard Welker pa rts and eq uipment. Assemblies that have been modified may have additional

requirements and specifications that are not listed in this manual.

1.2 Product Description

The Welker AP-3 Adjustable Probe is designed for use in systems where it is desirable to insert and retract the probe while the pipeline remains pressurized. When used with a pipeline isolation valve, the AP-3 can be safely inserted and retracted manually without interfering or venting pressure when operating pressure is reduced to the appropriate level.

Welker may custom design the AP-3 to suit the particular application and specifications of each customer.

IOM-009 MODELS: AP-3 and A P-3F REV: D 13839 West Bellfort St reet, Sugar L and, TX 77498 welker. com Servic e Departm ent 281.491.2331

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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. Please note that the specifications may vary depending on the customization of y our equipment.

Products Sampled

Materials of Construction

Maximum Allowable Operating Pressure

Maximum Allowable Insertion/Retraction Pressure

Pipeline Connection

Insertion Length

Options

Table 1: AP-3 Specifications

Gases and Liquids Compatible With the Materials of Construction

316/316LStainless Steel, PTFE, and Viton® Others Available

NPT: 1440 psig @ -20 °F to 120 °F (99 barg @ -28 °C to 48 °C) 150 ANSI (SS): 275 psig @ -20 °F to 100 °F (18 barg @ -28 °C to 37 °C) 300 ANSI (SS): 720 psig @ -20 °F to 100 °F (49 barg @ -28 °C to 37 °C) 600 ANSI(SS):1440 psig @ -20 °F to 100 °F (99 barg @ -28 °C to 37 °C) 1500 ANSI (SS): 3600 psig @ -20 °F to 100 °F (248 barg @ -28 °C to 37 °C)

6 mm Tubing: 1100 psig (75 barg) ¼" Tubing: 1000 psig (68 barg) ³∕₈" Tubing: 500 psig (34 barg) ½" Tubing: 250 psig (17 barg) ⁵∕₈" Tubing: 160 psig (11 barg) ¾" Tubing: 115 psig (7 barg) 1" Tubing: 65 psig (4 barg)

NPT

½" ¾"

Flanged Size:

¾", 1, 1½", 2", 3", or 4"

Rating:

150, 300, 600, or 1500 ANSI

1"

0–18" (0–45 cm) (Standard) Others Available

Beveled Probe Tip Outlet Valve Retraction Indicator Wires Scooped Probe Tip CECompliance NACECompliance

IOM-009 MODELS: AP-3 and A P-3F REV: D 13839 West Bellfort St reet, Sugar L and, TX 77498 welker. com Servic e Departm ent 281.491.2331

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1.4 Equipment Diagrams

Figure 1: Standard AP-3

Figure 2: AP-3 With Optional Retraction Indicator Wires

IOM-009 MODELS: AP-3 and A P-3F REV: D 13839 West Bellfort St reet, Sugar L and, TX 77498 welker. com Servic e Departm ent 281.491.2331

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Figure 3: AP-3 With Blind Flange

Figure 4: AP-3F With Optional Retraction Indicator Wires

IOM-009 MODELS: AP-3 and A P-3F REV: D 13839 West Bellfort St reet, Sugar L and, TX 77498 welker. com Servic e Departm ent 281.491.2331

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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.



1. A sample probe is recommended to extract sample from the center one-third (¹∕₃) of the pipeline in a location where

the product is well-mixed and will yield a representative sample. 2. For gas sampling applications, Welker recommends that the unit be installed in the top of the pipe. 3. For liquid sampling applications, Welker recommends that the unit be installed in the side of the pipe. 4. Handle the unit with care. Avoid bending and scratching the probe shaft, which has a polished surface that travels

through seals. 5. Operate the unit slowly and smoothly while inserting and retracting to avoid damaging the unit. 6. Take care not to close the pipeline isolation valve on the probe shaft while the shaft is inserted in the pipeline. This is

the most common cause of damage to Welker probes.

2.2 Preparing the AP-3 for Installation

1. Prior to installation, the length the probe shaft will need to travel inside the pipeline must be determined. Measure the

distance the shaft must travel from the top of the pipeline isolation valve to the desired insertion depth (e.g., the center

one-third (¹∕₃) of the pipeline) (Figure 5). This will be the shaft insertion length.



Figure 5: Determining Insertion Depth

 2. Pull up on the probe shaft to ensure that it is fully retracted. The safety stop at the tip of the probe shaft will be flush

with the base or flange face. 3.

Beginning at the top edge of the nut, measure along the probe shaft to the desired insertion length (Figure 1, Figure 2,

Figure 3, or Figure 4). Use a felt tip pen to mark this point.

IOM-009 MODELS: AP-3 and A P-3F REV: D 13839 West Bellfort St reet, Sugar L and, TX 77498 welker. com Servic e Departm ent 281.491.2331

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4. Carefully slide the nut and tube union up the probe shaft to the desired insertion length, taking care not to scratch the

probe shaft. 5. Holding the tube union with a wrench, use another wrench to tighten the nut onto the tube union. The ferrule inside

the nut will clasp onto the shaft, locking the tube union in place.



This procedure ensures that the insertion length will be mechanically limited by the tube union assembly.

 6. As necessary, cut off excess tubing from the shaft. Beginning at the top edge of the nut, measure approximately two

inches (2") along the shaft. Use a felt tip pen to mark this point. 7. Using tubing cutters, remove the excess tubing at the marked point, and then file and smooth the cut edge of the

probe shaft. 8. 9.

If excess tubing was cut off, return outlet valve A to the top of the probe shaft (Figure 1, Figure 2, Figure 4).

Ensure that outlet valve A is closed (Figure 1, Figure 2, Figure 4).

IOM-009 MODELS: AP-3 and A P-3F REV: D 13839 West Bellfort St reet, Sugar L and, TX 77498 welker. com Servic e Departm ent 281.491.2331

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2.3 Installing the AP-3

Pipeline pressure must be reduced to the maximum allowable insertion/retraction pressure prior to inserting and retracting the AP-3.



The maximum allowable insertion/retraction pressure varies according to shaft size. Pipeline pressure should be reduced to at or below:

•

1100 psig (75 barg) for 6 mm tubing.

•

1000 psig (68 barg) for ¼" tubing.

•

500 psig (34 barg) for ³∕₈" tubing.

•

250 psig (17 barg) for ½" tubing.

•

160 psig (11 barg) for ⁵∕₈" tubing.

•

115 psig (7 barg) for ¾" tubing.

•



65 psig (4 barg) for 1" tubing.

 1.

If applicable, ensure that outlet valve Ais closed (Figure 1, Figure 2, or Figure 4). 2. Ensure that the probe shaft is retracted. 3. Secure the AP-3 to a full port pipeline isolation valve. 4. Slowly open the pipeline isolation valve. Check for leaks and repair as necessary. 5. To manually insert the AP-3, push down on the top of the probe shaft until the tube union assembly reaches the base or

flange. If manually inserting an AP-3 with blind flange, push down on the top of the probe shaft until the base reaches

the blind flange.



DONOT release the AP-3 until the tube union has been secured to the base or flange.



Push the shaft straight down and do not allow the shaft to bend.

 6. Secure the AP-3 in place by tightening the tube union assembly into the base or flange. If manually inserting a AP-3 with

blind flange, secure the AP-3 in place by tightening the base into the blind flange. 7. Install customer-supplied tubing or other fittings to the outlet. 8. Restore the pipeline to full operating pressure. 9.

If applicable, open outlet valve A (Figure 1, Figure 2, or Figure 4).

IOM-009 MODELS: AP-3 and A P-3F REV: D 13839 West Bellfort St reet, Sugar L and, TX 77498 welker. com Servic e Departm ent 281.491.2331

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2.4 Retracting the AP-3

Pipeline pressure must be reduced to the maximum allowable insertion/retraction pressure prior to inserting and retracting the AP-3.



The maximum allowable insertion/retraction pressure varies according to shaft size. Pipeline pressure should be reduced to at or below:

•

1100 psig (75 barg) for 6 mm tubing.

•

1000 psig (68 barg) for ¼" tubing.

•

500 psig (34 barg) for ³∕₈" tubing.

•

250 psig (17 barg) for ½" tubing.

•

160 psig (11 barg) for ⁵∕₈" tubing.

•

115 psig (7 barg) for ¾" tubing.

•



65 psig (4 barg) for 1" tubing.

 1.

If applicable, close outlet valve A (Figure 1, Figure 2, or Figure 4). 2. Disconnect the customer-supplied tubing or fittings attached to the outlet. 3. Firmly push down on the top of the probe shaft while slowly loosening the tube union assembly from the base or

flange. If retracting an AP-3 with blind flange, firmly push down on the top if the probe shaft while slowly loosening the

base from the blind flange.



Failure to ensure that adequate pressure is applied to the top of the AP-3 prior to retraction could result in unexpected retraction of the shaft at great speed, which could damage the unit or injure the operator.

 4. The AP-3 will begin retracting from the pipeline.

5. Pull up on the probe shaft to ensure that it has been fully retracted. 6. Close the pipeline isolation valve. 7. The AP-3 is now ready to be removed from the pipeline isolation valve for maintenance or to be moved to another

location.

IOM-009 MODELS: AP-3 and A P-3F REV: D 13839 West Bellfort St reet, Sugar L and, TX 77498 welker. com Servic e Departm ent 281.491.2331

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3.1 Before You Begin

SECTION 3: MAINTENANCE

1.

Maintenance is necessary if a leak occurs at the base or flange.

2. 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. Welker recommends having the following tools available for maintenance. Please note that the exact tools required may

vary by model.

a. Adjustable Wrench

b. File or Fine Grit Sandpaper

c. Seal Pick

d. Tubing Crimp and Accessories

e. Wire Cutters

3.2 Maintenance

If a leak occurs at the base or flange, the AP-3 requires maintenance.



 1.

Prior to performing maintenance, the AP-3 must be removed from the pipeline. See Section 2.4, Retracting the AP-3, for

instructions on retracting the probe shaft and removing the unit from the pipeline.

IOM-009 MODELS: AP-3 and A P-3F REV: D 13839 West Bellfort St reet, Sugar L and, TX 77498 welker. com Servic e Departm ent 281.491.2331

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Figure 6: Maintenance Diagram — Standard AP-3

Figure 7: Maintenance Diagram — AP-3 With Optional Retraction Indicator Wires

Figure 8: Maintenance Diagram — AP-3 With Blind Flange

IOM-009 MODELS: AP-3 and A P-3F REV: D 13839 West Bellfort St reet, Sugar L and, TX 77498 welker. com Servic e Departm ent 281.491.2331

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Figure 9: Maintenance Diagram — AP-3F With Optional Retraction Indicator Wires

2. 3.

If applicable, cut the retraction indicator wires and remove them from the AP-3 (Figure 7 or Figure 9).

If applicable, remove outlet valve A from the probe shaft (Figure 6, Figure 7, or Figure 9). 4. Loosen the nut with ferrule. 5. Using tubing cutters, cut the probe shaft below the crimp made by the ferrule inside the nut. 6. File the burr left by the tubing cutters and lightly sand the area. This will allow the probe shaft to slide out of the base or

flange. 7. Slide the probe shaft out through the bottom of the base or flange. 8. Replace the O-ring and back ups in the base or flange. 9. Carefully insert the probe shaft through the bottom of the base or flange.

10. Slide a new ferrule onto the shaft. 11. Return the nut to the shaft. 12. 13.

If applicable, return outlet valve A to the probe shaft (Figure 6, Figure 7, or Figure 9).

If applicable, connect retraction indicator wires from the base or flange to the top of the probe shaft (Figure 7 or Figure

9).

14.

The AP-3 may now be installed to the pipeline. See Section 2.2, Preparing the AP-3 for Installation, and Section 2.3,

Installing the AP-3, for instructions on installing the AP-3 to the pipeline.

IOM-009 MODELS: AP-3 and A P-3F REV: D 13839 West Bellfort St reet, Sugar L and, TX 77498 welker. com Servic e Departm ent 281.491.2331

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APPENDIX A: REFERENCEDORATTACHEDDOCUMENTS

WelkerInstallation, Operation, and Maintenance (IOM) Manuals suggested for use with this unit:

l IOM-105: Welker NV-1 and NV-2 Instrument Valves

Other Installation, Operation, and Maintenance (IOM) Manuals suggested for use with this unit:

l Anderson Greenwood H7/H71 Hand Valves (Welker IOM-V414) l Apollo Valves 76-100 Series Stainless Steel Ball Valve with Mounting Pad 1/4"-1" (Welker IOM-V141) l Generant Inc. Forged Needle Valve Series FNV (Welker IOM-V240) l Parker Hannifin Corporation Ball and Plug Valves (Welker IOM-V213) l Parker Hannifin Corporation Ball Valves B Series (Welker IOM-V365) l Swagelok Company Ball Valves 60Series (Welker IOM-V018) l Swagelok Company Check Valves C, CA, CH, CP, and CPASeries (Welker IOM-V076) l Swagelok Company Integral-Bonnet Needle Valves O, 1, 18, 20, and 26 Series (Welker IOM-V136) l Swagelok Company One-Piece Instrumentation Ball Valves 40G Series and 40 Series (Welker IOM-V085) l Swagelok Company Severe-Service Union-Bonnet Needle Valves N Series and HNSeries (Welker IOM-V347) l Swagelok Company Trunnion BallValves 83 Series and H83 Series (Welker IOM-V359)

Welker drawings and schematics suggested for use with this unit:

l Assembly Drawing: AD126BU (AP-3 With Retraction Indicator Wires) l Assembly Drawing: AD126CO (Standard AP-3) l Assembly Drawing: AD126DR (AP-3F With Retraction Indicator Wires) l Assembly Drawing: AD126EH (AP-3 Mounted on Blind Flange)

IOM-009 MODELS: AP-3 and A P-3F REV: D 13839 West Bellfort St reet, Sugar L and, TX 77498 welker. com Servic e Departm ent 281.491.2331

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NOTES

____________________________________________________________________________________________________



13839 West Bellfort Street

Sugar Land, TX77498

Phone: 281.491.2331

IOM-009 MODELS: AP-3 and A P-3F REV: D 13839 West Bellfort St reet, Sugar L and, TX 77498 welker. com Servic e Departm ent 281.491.2331

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