maintenance flare step by step

8/11/2019 Maintenance Flare step by step

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13839 West BellfortSugar Land, TX 77498-1671

(281) 491-2331 - Office(800) 776-7267 - US Only

(281) 491-8344 - Faxhttp://www.welkereng.com

2012 Welker, Inc. All Rights Reserved.

Installation, Operation, and

Maintenance Manual

Welker F lare Stack Sampling SystemModel

FSS06607

Drawing No.: LS3075.1

Manual No.: IOM-150

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.


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IOM-150 Last Updated: 05/02/2012

PART #: Flare Stack Sampling System Page 3 of 8Rev: -

Section 1:

SPECIFICATIONS

We appreciate your business and your choice of Welker

products. The installation, operation, andmaintenance 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 performanceprior to use.*

If you have any questions, please call 1-800-776-7267 (USA) or 1-281-491-2331.

*The following procedures have been written for use with standard Welkerparts and equipment. Assemblies that

have been modified may have additional requirements and specifications that are not listed in this manual.

The Welker Flare Stack Sampling System utilizes an auxiliary gas supply, an eductor, and a

Welker LSS-1 sampler to collect samples from a non-pressurized or vacuum source. The FSSsystem is electronically controlled and can be set to sample proportional-to-flow.

The eductor and auxiliary gas are used to create a flow loop that continually presents fresh product

to the LSS-1, allowing for collection of accurate, representative samples. The LSS-1 sampler collectssample from the flowing stream of product and deposits the sample into a sample container for

laboratory analysis.

Welkermay custom design the Flare Stack Sampling System to sui t the parti cular application

and specif icati ons of each customer.


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Table 1: System Specifications

Products Sampled

Gas or Liquid

Materials of Construction 316 Stainless Steel, Viton, PTFE

ConnectionsSample Inlet, Sample Outlet, Relief Valve, Return Port, Auxiliary Gas

NPT

Maximum Allowable Operating Pressure1480 psi @ -20oto 100oF

(102 bar @ -29 to 38oC)

Instrument Regulator Maximum Inlet

Pressure

3600 psi @ -20oto 120oF

(248 bar @ -29oto 49oC)

Instrument Regulator Output Range20 to 100 psi @ -20oto 100oF

(1.4 to 6.9 bar @ -29oto 38oC)

Figure 1: Recommended General Arrangement


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Section 2:

INSTALLATION & OPERATIONS

A sample probe is recommended to extract the sample from the center one-third (1/3) of the

pipeline. The sample probe should be located in the least turbulent area of the flowing stream as

available (i.e., not in a header or blow-down stack and away from obstructions, elbows, or

partially closed valves), in an area where the sample is well-mixed and representative of theproduct.

1. Mount the sample panel in a location convenient for sample collection.

2.

Connect the probe in the product pipeline to the product inlet (P1) on the manifold.

Figure 2: Manifold Block Connections

3. Connect the product outlet (P2) on the manifold to the P2line of the probe, if supplied, or flarefor discharge.


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4. Connect instrument air to the instrument supply port.5. Connect a sample container to the sample outlet.

6. Connect 110VAC power to the ATC-354 Electronic Digital Counter. Refer to the Installation,

Operation, and Maintenance Manual for the ATC-354 for more detailed power connectioninstructions as necessary.

7. Connect dry contacts from the PLC to the explosion proof electrical enclosure.

Figure 3: Electrical Connections

1. Close the Product Outlet Valve.

2. Open the connection to the instrument air supply.

3. The relief and regulator should be set by the manufacturer prior to shipment. If not set, adjust theregulator until pressure reaches approximately 40 psi as indicated by the pressure gauge. Set the

relief valve to approximately 50 to 60 psi. Refer to the Installation, Operation, and Maintenance

Manualfor the WelkerRV-1 Relief Valve for more detailed instructions as necessary.

4. If using a helium-filled sample container, rather than a vacuumed sample container, open the

sample container outlet valve to release the helium from the container.

5. Open the sample container inlet valve.

6.

Open the probe connection.7. Open the product outlet/return connection.

8. Slowly open the Product Outlet Valve, continuing until the flow indicator indicates flow.

9. Turn on power to the ATC-354 digital counter.

10.Program the PLC to the desired number of contacts between samples.11.Check for leaks and repair any necessary. If no leaks are present, the system is now operational.


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Section 3:

MAINTENANCE

1.

Welker

recommends that the unit have annual maintenance under normal operatingconditions. In cases of severe service, dirty conditions, excessive usage, or other unique

applications that may lead to excess wear on the unit, a more frequent maintenance schedule may

be appropriate.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.

3. All maintenance and cleaning of the unit should be done on a smooth, clean surface.

1. During system operation, check for leaks and repair as necessary.

2. Periodically clean the filter and replace the filter cartridge as necessary. Refer to the Installation,

Operation, and Maintenance Manualfor the NuproInline Filter for cleaning and maintenance

instructions.

3. Refer to the Installation, Operation, and Maintenance Manualfor the WelkerLSS-1 Sampler

for maintenance instructions for the sample pump.

4. Refer to the Installation, Operation, and Maintenance Manual for the Welker

IR-4SSInstrument Regulator for maintenance instructions for the instrument regulator.

5.

Refer to the Installation, Operation, and Maintenance Manual for the Welker

RV-1 ReliefValve for maintenance instructions for the relief valve.

6. Refer to the Installation, Operation, and Maintenance Manual for the Fox

Mini-Eductor formaintenance instructions for the eductor.

7. Refer to the Installation, Operation, and Maintenance Manual for the Shawnee ATC-354

Electronic Counter for maintenance instructions for the electronic counter.8. Refer to theInstallation, Operation, and Maintenance Manualfor the Skinner

3-Way Valve for

maintenance instructions for the solenoid.

9. Refer to the Installation, Operation, and Maintenance Manual for the Wallace & Tiernan

Armored Purge Meter for maintenance instructions for the flow indicator.


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Section 4:

APPENDIX

WelkerInstallation, Operation, and MaintenanceManuals suggested for use with this unit:

IOM-064: LSS-1 Liquid Sample Pump

IOM-025: IR-4SS Instrument Regulator

IOM-033: RV-1 Relief Valve

OtherInstallation, Operation, and MaintenanceManuals suggested for use with this unit:

ATC-354: ShawneeATC-354 Electronic Counter (Welker IOM-V034)

IOM7304: Parker

Skinner

3-way Valve, 120VAC (Welker IOM-V016) SS-6TF-140: Swagelok

Nupro

Inline Filter (Welker IOM-V035)

401A: FoxMini Eductor (Welker IOM-V010)

5120M1: Siemens

Wallace & Tiernan

Armored Purge Meter (Welker IOM-V033)

Welkerdrawings and schematics suggested for use with this unit:

System Drawing: LS3075.1

13839 West BellfortSugar Land, TX 77498-1671

Phone: (281) 491-2331Fax: (281) 491-8344

Toll Free: (800) 776-7267Web Page:www.welkereng.com
http://www.welkereng.com/http://www.welkereng.com/http://www.welkereng.com/

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