abc OPERATING, INSTALLATION & MAINTENANCE MANUAL FOR SERIES 210 HI-TEMP SAMPLER 4 150LB BITUMEN SAMPLER

Transcription

1 abc OPERATING, INSTALLATION & MAINTENANCE MANUAL FOR SERIES 210 HI-TEMP SAMPLER 4 150LB BITUMEN SAMPLER This Jiskoot Product is designed to provide outstanding service if correctly installed, used and maintained recognising the effects of the process conditions (temperature, pressure, wax/pour point, sediment, etc.). 0 First Issue MJD P.Whittle 23/08/2001 Issue Revision History Issued Approved Date No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical, for any purpose, without the express written permission of Jiskoot Autocontrol Ltd Jiskoot Autocontrol Ltd. All rights reserved.

2 TABLE OF CONTENTS 1 WARRANTY INTRODUCTION OPERATING INSTRUCTIONS PRE-OPERATIONAL CHECKS GLOSSARY OF SPECIAL TERMS FULL FUNCTIONAL DESCRIPTION DESCRIPTION PRINCIPLE OF OPERATION UTILITIES REFERENCE INSTALLATION DETAILS SAMPLER INSTALLATION SERVICES ANCILLARY EQUIPMENT INSTALLATION MAINTENANCE AND TROUBLESHOOTING HEALTH AND SAFETY PRECAUTIONS WEEKLY MAINTENANCE ANNUAL MAINTENANCE (OR AS DETERMINED BY SITE CONDITIONS) OVERHAUL INSTRUCTIONS TORQUE SETTINGS BOTTOM PLUG SUB-ASSEMBLY ACTUATOR SUB-ASSEMBLY REASSEMBLY OF ACTUATOR AND BOTTOM PLUG SUB-ASSEMBLIES TO MAIN BODY FAULT DIAGNOSIS SAMPLER DOES NOT OPERATE SAMPLER OPERATES BUT DOES NOT PRODUCE A SAMPLE AIR LEAKS FROM ACTUATOR PROCESS FLUID LEAKS DRAWINGS AND PARTS LISTS DISCLAIMER...12

3 1 Warranty This product should be supplied with a warranty card. Please complete and return it to register for warranty support. In the event it is missing, to register for support, please contact us on +44 (0) or support@jiskoot.com, quoting the Jiskoot Order Number or Serial No with the following information: Date installed Full installation site details, including contact details Maintenance and operator contact details (where different from above) Product comments/feedback If the product has been supplied as part of a Jiskoot system or assembly, please complete the warranty card for the system. 2 Introduction The Jiskoot Series 210 Hi-Temp Sampler provides a means of extracting a sample of liquids such as bitumen and similar high line temperature products flowing in a pipeline. Primarily designed for applications where air pressure is available to provide the motive power, the 210 is installed directly into the main pipeline. To enable high temperature samples to be extracted the Jiskoot 210 Hi-Temp Sampler incorporates several unique features: 1. The actuator is mounted well away from the heat source but is otherwise of the well proven 210 Series origin. 2. There are no seals in the actual sample capture/discharge mechanism, only very close tolerance metal-to-metal clearances. It follows that for optimum sample volume repeatability performance, the line pressure should be kept reasonably stable during the transfer of a particular batch. The 210 Hi-Temp Sampler has raised face connections for fitting directly between two 4" 150lb Flanges, and is suitable for line pressures up to 19 Bar (275 psi). The Sampler extracts nominal 1cc samples at the following rates: Sampler Type Version Max. Sampling Rate (Depending on Velocity) Series 210 Standard 120 Samples/min Due to the sampler's seal-less construction, the sample size will slightly decrease with the line pressure and viscosity - due to a change in differential pressure between the line pressure and the captured sample during the discharge stroke against the fixed 20 Bar check valve. The sample size has been adjusted to provide a nominal 1cc at 20 Bar line pressure for 15Cst product. Please use the Sampler Serial Number when ordering spare parts. This may be found in the project information supplied in the preface of this handbook or on the label attached to the Sampler.

4 3 Operating Instructions The Sampler must be installed in accordance with the Installation Details, and be connected to a suitable sample receptacle. To operate, the Sampler requires a regulated air supply at 5-8 Barg ( psig) and a signal to energise the Sampler Solenoid to actuate the sampler at the required intervals. Control of the Sampler including changeover of Sample Receivers, will be determined by the type of Sampler Control System being used. 3.1 Pre-Operational Checks It is recommended that the following checks be carried out before operating the Sampler: Check all connections (sample line, pneumatic, and electrical) to ensure that they are correct and secure. Note: Ensure that approved blanking plugs are fitted into any unused cable entries in the junction box. Failure to do so will invalidate the hazardous area certification of the equipment. Switch on mains air supply to the air regulator. Adjust the regulator to give the correct air pressure. Check that the sample outlet of the Sampler is not blocked or isolated from the sample outlet line. Operation of the sampler with the sample outlet blocked or prolonged operation without fluid may cause damage to the sampler. Check that the pulse duration of the electrical signal to the Solenoid Valve is correct (i.e. 500 milliseconds second minimum). If these checks are satisfactory and there is product in the pipeline, the Sampler may be operated by pulsing the Solenoid Valve. Continue to operate the Sampler until all trapped air is displaced and the sampling system is completely filled with fluid. This will require approximately thirty operations of the Sampler. Set the Controller as detailed in the Sampler Controller handbook. Connect the Sample Receiver(s) to the delivery hose(s). The system is now ready to commence sampling. 4 Glossary of Special Terms CAPTURE TUBE GRAB HP LOST MOTION MAIN BODY SAMPLE EJECTOR PIN Outer tube that moves to isolate the sample grab. The action of taking an individual sample (normally 1cc) from the pipeline High Pressure Mechanical device in actuator to convert two linear motions in sequence from one. Central section of sampler that is connected into the Pipeline - fluid to be sampled flows through it. Inner "piston" that drives out the sample through a passage in the bottom plug. 5 Full Functional Description

5 5.1 Description Refer to Drawing B The 210 Hi-Temp Sampler extracts a sample by capturing it and ejecting it. The Sampler has a single piston, air actuator with an integral lost-motion mechanism that produces the patented three-step sample grab action (see Section 2.2). 5.2 Principle of Operation The 210 Cell Sampler operates on Jiskoot s standard 3-step principle, using a pneumatically actuated piston to provide the motive power. Step 1. Both the Capture Tube (92) and the Sample Ejector Pin (96) are at the top of their stroke. By applying pressure above the Piston in the Actuator, the Piston/Capture Tube Assembly is forced to move downwards over the Sample Head Pillar (81). This action isolates the 1cc sample inside the Capture Tube. Step 2. As the Piston continues to move downwards, the Catchplate strokes the Sample Ejector Pin actuator. The Sample Ejector Pin is forced to move downwards with the Capture Tube. Pressure is exerted on the isolated sample grab. As the pressure of the isolated sample grab increases, the Check Valve (83) opens. The sample is forced through the Check Valve Assembly, and subsequently out of the Sampler through the port in the bottom of the check valve housing (82). The function of the Check Valve is to isolate the taken sample grab from the line. During this step of the sampler operation, fluid flow continues through the main body of the Sampler around the Capture Tube. Step 3. By applying air pressure to the Bottom Actuator Housing, the Piston is forced to move upwards. Therefore both the Capture Tube and Sample Ejector Pin are moved to the top of their strokes. With the Piston at the top of its stroke, a clear path is again provided for fluid flow through the main body of the Sampler, and the Sampler is ready for the next grab to be initiated. 6 Utilities Reference Air Supply (Lubricated) Air Consumption* Solenoid Voltages Available: Solenoid energisation time Maximum Sampling Rates* AC DC Power Consumption 4-10 Barg ( psig) 0.8 m 3 /hr or 0.47 scfm (5 Barg at 30 grabs/min) Volts 50/60 Hz 24 Volts DC 10 Watts 500 ms 120 Samples/min * Maximum grab rate, air consumption and supply requirements are dependent on process conditions, i.e. line pressure and viscosity. 7 Installation Details 7.1 Sampler Installation

6 CORRECT INSTALLATION OF THE SAMPLER AND ANCILLARY EQUIPMENT IS CRITICAL TO THE PERFORMANCE OF THE SAMPLING SYSTEM. IF IN ANY DOUBT, PLEASE CONSULT JISKOOT AUTOCONTROL LIMITED FOR RECOMMENDATIONS. The 210 Hi-Temp Sampler is intended to be installed directly into the product pipeline. The Sampler is designed to be fitted between a pair of 4 150# RF flanges as shown in Drawing B All 8 bolts must be fitted. For optimum performance, the Sampler should be installed with its axis vertical and with the sample outlet connection at the bottom. 7.2 Services A compressed air supply. An electrical signal to the control solenoid. Suitable trace heating to cover the sampler spool assembly and the sample line to the receiver. 7.3 Ancillary Equipment Installation The Series 210 Hi-Temp Sampler requires certain ancillary equipment to operate it. As a minimum, an air pressure regulator, solenoid valve and junction box. This equipment is mounted adjacent to the sampler. Various other items may be used to enhance the operation and maintenance of the system. The ancillary equipment, described in Section 3, is mounted adjacent to the sampler. 1. Fit the brackets complete with the ancillary equipment to a suitable support. 2. Connect the two ports of the Actuator to the air control valve. Ensure that when the coil of the valve is de-energised, air is supplied to below the actuator piston. 3. Connect the outlet port of the Sampler to the sample receiver(s). Note: The top of the Sample receiver must be below the level of the Sampler. The tubing must slope downwards towards the Sample Receiver, and be as straight and short as possible. Heat-trace the tubing to 200 o C. Use the table as a guide to tubing size. Sample Tubing Length Up to 200 Cst Over 200 Cst Up to 1.5m 1/4" O.D. 1/4" O.D. 1.5m to 3m 1/4" O.D. 3/8" O.D. Over 3m 3/8" O.D. 1/2" O.D. 4. Connect the air supply to the inlet port (¼" NPT) of the pressure regulator. 5. Connect solenoid coil cable to an adjacent junction box (supplied by customer), ensuring the correct fuse is fitted in the supply circuit (Refer to section 6.3.2). 6. Removal of the ancillary equipment is generally the reverse of the above procedure Air Pressure Regulator The regulator provides adjustment of the air pressure, indicated on the pressure gauge fitted to the Unit. The ports are threaded ¼" NPT.

7 7.3.2 Solenoid Valve A solenoid operated, spring return, 5 port 2 way control valve is used to switch air to and exhaust air from the sampler actuator. The coil assembly is certified for use in a Zone I IIB T4 hazardous area. The appropriate fuse must be included in the coil supply circuit: 24V DC.Coil : 1A V AC Coil : 125mA V AC Coil : 63mA A medium slow blow fuse must be used. Note: Failure to incorporate a fuse may invalidate the hazardous area certification of the solenoid valve. The ports are threaded ¼" NPT. 8 Maintenance and Troubleshooting 8.1 Health and Safety Precautions The 210 Hi-Temp Sampler may be used in applications involving carcinogenic or other hazardous products. Care must be taken to avoid contamination by any product trapped within the internal components that may be released as the Sampler is stripped down. To enable the check valve housing, bottom plug and the Actuator Assemblies to be removed, it may be necessary to heat the Sampler to melt any solidified product. Once two subassemblies have been unscrewed, a solvent bath may be used to release the product from the individual components. The application of heat and the use of any solvents must be undertaken in accordance with local health and safety regulations. 8.2 Weekly Maintenance Regular maintenance is limited to ensuring the Sample Ejector Assembly is filled with approximately 50cc s of high melting point grease via the Grease Nipple (49) and draining excess moisture from the air filter/regulator (if fitted with drain). 8.3 Annual maintenance (or as determined by site conditions) The 210 Hi-Temp Sampler is designed to operate continuously for a period of about 1,000,000 grabs or 12 months before a major overhaul, however this will be affected by the type of product being sampled, particularly the amount of particulate matter, and therefore can not be guaranteed. The service intervals will therefore need to be determined from the experience gained on the particular application. The Sampler should be removed from the pipeline and taken to a clean area for servicing. It is essential that soft vice jaws are used whenever components are required to be held, and that all components, particularly those with sealing faces are thoroughly cleaned of dirt and other contamination by degreasing and drying prior to re-assembly. Special Tools, as listed in Section 9, are available to assist in fitting some components and seals. Failure to use the correct tools may damage seals and other components, and will have a direct effect on the future performance of the Sampler 8.4 Overhaul Instructions

8 The instructions for strip down and reassembly are for the standard 4 version of the 210 Hi- Temp Sampler, but are applicable to all variants, as they will generally only vary in the size of the Body and the length of the Capture Tube, Support Pillar and the Sample Head Pillar. See Section 9 for details of Spares Kits and the Special Tools required to overhaul the Sampler. Separate details are given for overhaul of individual sub-assemblies. The item numbers in brackets in each section are the item numbers of the components shown on the General Assembly Drawing B The complete overhaul should be carried out in the following order: Step Description 1 Remove and overhaul Bottom Plug Sub-Assembly 2 Remove and overhaul Actuator Sub-Assembly 3 Replace Actuator Assembly 4 Replace Bottom Plug assembly NOTE: It is essential that soft vice jaws are used whenever components are required to be held, and that all components, particularly those with sealing faces are thoroughly cleaned of dirt and other contamination by degreasing and drying prior to re-assembly. If any of the sliding surfaces are damaged, leakage will occur from the seals. All joints, 'O' Rings and moving parts must be lubricated on assembly using a general purpose grease such as Castrol Spheerol B2 grease or an equivalent lithium based water-resistant grease. Jiskoot recommend that all screwed components be lubricated with copper grease on assembly to prevent seizure. 8.5 Torque Settings The following torque settings should be used in the reassembly of the sampler: Screw Location Size Torque Bottom Actuator Housing to M8 * 25mm Cap Head (Item 52) 25Nm/18.4lbfft Support Pillar Lower Piston Rod to Capture Tube 75Nm/55.3lbfft Sample Pin Actuator to M5 * 25mm Cap Head (Item 33) 10Nm/7.4lbfft Catchplate Actuator Top to Bottom Housing Pre August Nm/11.1lbfft M6 * 25mm Cap Head (Item 34) Post August 1992 M8 * 30mm Cap Head (Item 34) 25Nm/18.4lbfft Sample Ejector Head to Sample Pin Actuator 60Nm/44.5lbfft 8.6 Bottom Plug Sub-Assembly To enable the Bottom Plug to be unscrewed from the Main Body of the Sampler, it may be necessary to heat the Sampler to melt any solidified product.

9 Using C Spanner, Tool A, unscrew and remove the Bottom Plug (78) from the bottom of the Main Body (62). Remove the Copper Washers (75) and the Sample Head Pillar (81) from the Main Body, noting the number and location of the Copper Washers. Unscrew and remove the Check Valve Housing (82) complete with the Dowty Seal (48) from the Bottom Plug. Unscrew the Adjuster (88) from the end of the Check Valve Housing to release the Spring (84), Check Valve Pin (86) and Ball (83). Clean all components and examine for wear, particularly the Ball and the seat in the bore of the Check Valve Housing. Replace any damaged components. Reassemble the Check Valve Assembly. The correct pre-load on the Check Valve Assembly is obtained with the Adjuster (88) fully tightened in the Check Valve Housing. Fit the Check Valve Housing Assembly to the Bottom Plug, using a new Dowty Seal. Loosely refit the Bottom Plug Assembly into the Main Body, using new copper washers between the Bottom Plug, the Sample Head Pillar and the Main Body. Note: Do not tighten at this stage. 8.7 Actuator Sub-Assembly The Actuator sub-assembly must be removed from the Support Pillar (52) before the Support Pillar and Seal Gland (68) can be unscrewed from the Main Body. Before attempting to overhaul the Actuator, it will be necessary to unscrew the Gland Nut (69) to release the loading on Capture Tube (92) caused by the Graphite Seals (70) Removal of Sample Ejector Head Remove the Gaiter (47) to expose the machined flats on the Sample Pin Actuator (25) through the Spring (41). Hold the Sample Pin Actuator (25) with a 19mm (3/4 ) A/F open-ended spanner on the flats and, using C Spanner, Tool A, in the slot in the Sample Ejector Head (28), loosen the Sample Ejector Head (28) by gently tapping the C Spanner with a soft-faced hammer. The Sample Ejector Head unscrews in an anti-clockwise direction when viewed from above. Remove the Sample Ejector Head (28) and Sealing Washer (33) from the Sample Pin Actuator. Remove the Spring and remove the two halves of the Split Collar (42). Apply slight air pressure to the upper port in the Bottom Housing (18) to move the Piston (23) to the top of its stroke Overhaul of Actuator Unscrew the Gland Nut (69) to release the loading on Capture Tube (92) caused by the Graphite Seals (70). Remove the six M8 screws that attach the Top Housing (16) to the Bottom Housing (23). Apply slight air pressure to the Lower Port in the Bottom Housing and withdraw the complete assembly, comprising Piston (23), Catchplate (26), Sample Pin Actuator (25), Lower Piston Rod (27), Sample Ejector Pin (96), Capture Tube (92) and Top Housing (16) from the Lower Actuator Housing.

10 Note: Heat may be required to release the Capture Tube from any solidified product in the Guide Bush (72). Place sub-assembly to one side. Mark the location of the Support Pillar (52) to Bottom Housing (18) in order that the ports will face in the original direction on reassembly. Remove the M8 cap head screws retaining the Support Pillar from the Bottom Housing. Clean the Bottom Housing. Replace Double Delta Seal (37) in the Bottom Housing. Note: From 1999, Item 37 was replaced by a Double Delta Seal, Part No This Seal is fully interchangeable with all options previously supplied. Unscrew the Support Pillar (52) from the Main Body (62), using a Tommy Bar through the ventilation holes in the Support Pillar. Using a large C Spanner, unscrew the Seal Gland (68) from the Main Body. If the Seal Gland unscrewed with the Support Pillar, hold the Seal Gland in a vice and unscrew from the Support Pillar. Remove the Gland Nut (69) and the Graphite Seal (70), noting the number of pieces of seal. Clean and examine all components for wear. If considered necessary, remove the Guide Bush (72) from the Main Body, noting the number and position of the Copper Washers (75). Note: To enable the Guide Bush to be removed from the Main Body of the Sampler, it may be necessary to heat the Sampler to melt any solidified product. Replace the Guide Bush (72) in the Main Body (62) using new Copper Washers (75). Pack the correct quantity of Graphite Seals (70) in the Seal Gland (68), grease the thread of the Seal Gland with copper grease, and screw into Body. Loosely fit the Gland Nut (69). Reassemble the Support Pillar (52) to the Seal Gland and tighten using a Tommy Bar through the ventilation holes. Reassemble the Support Pillar (52) to the Bottom Actuator (18), ensuring the correct orientation of the Pillar to the Actuator. Torque up the M8 cap head screws to the specified torque Overhaul of Piston/Sample Pin Actuator/Lower Piston Rod Assembly Hold the Lower Piston Rod (27) in a soft jawed vice - taking care to protect its surface. Remove the Top Housing, complete with the Sealing Bush (20) and Lock Ring (32), from the Sample Pin Actuator (25). Using a suitable rod of soft material e.g. Delrin, push the bottom end of the Sample Ejector Pin (96) up the Capture Tube (92) to expose the Split Collet (30) at the opposite end of the Sample Ejector Pin. Remove the two halves of the Split Collet and any Shims fitted underneath it. Retain Shims for reassembly.

11 Examine the Split Collet groove in the Sample Ejector Pin. Ensure that the groove has no burrs or damage, which might impede removal of the Sample Pin Actuator. Remove the six M5 screws retaining the two halves of the Catchplate (26) to the Piston (23) and Lower Piston Rod (27). Remove the Catchplate and Piston. Remove the Sample Pin Actuator (25) from the Sample Ejector Pin. Remove the Sample Ejector Pin by tapping it gently downwards through the Capture Tube. Unscrew and remove the Seal Nut (29) using Lower Piston Rod Seal Nut Peg Spanner, Tool E. Remove the Balseal (43), Seal Ring (31) and Upper Sample Ejector Pin Quadring (34) from the Lower Piston Rod. The Balseal (43) may be removed from the Lower Piston Rod by gently tapping it upwards using the top of the Sample Ejector Pin. Remove the O Ring (50) from inside the Seal Ring cavity in the Lower Piston Rod. Clean all components. Examine all tubes and sealing surfaces for wear, scratches and straightness. Any components with damage in the sealing area must be replaced. Note: If the Capture Tube is to be replaced, a complete sub-assembly including the Lower Piston Rod must be obtained from Jiskoot. Fit 'O' Ring (Part No ) supplied in the Spares Kit, to the Split Collet groove on the Sample Ejector Pin to prevent damaging the Balseal as it is pushed over the groove. Fit the new Upper Sample Ejector Pin Balseal (43) onto the Sample Ejector Pin (96) from the top of the Sample Ejector Pin. Ensure that the Balseal is fitted with the seal spring facing towards the bottom of the seal recess in the Lower Piston Rod (27), as shown on the drawing. Insert the Sample Ejector Pin into the Lower Piston Rod/Capture Tube Assembly, carefully positioning the Balseal (43) in the seal recess in the Lower Piston Rod, using Upper Sample Ejector Pin Seal Assembly Tool, Special Tool L. Fit the O Ring (50) into the recess in the Lower Piston Rod (18), using the Seal Ring to guide into position. Note: From 1999, Item 34 was replaced by a Quadring, Part No This Seal is fully interchangeable with all options previously supplied. Fit the Seal Ring (31), Quadring (34), and Seal Nut (29) to the Sample Ejector Pin above the Balseal (43). Screw the Seal Nut (29) into the Lower Piston Rod (27) and tighten using Lower Piston Rod Seal Nut Peg Spanner - Tool E Reassembly of Piston/Catch Plate/Actuator Assembly Fit Piston (23) to Lower Piston Rod (27), ensuring Piston is correct way round. Fit new 'O' Ring (22) to bore of the Sample Pin Actuator (25). Fit Sample Pin Actuator (25) and Catchplate Assembly over the Sample Ejector Pin and attach to the Piston/Lower Piston Rod Assembly using the six new M5 * 25 cap head screws supplied in Spares Kit, ensuring Sample Pin Actuator is correctly retained by the Catchplate.

12 Note: Care must be taken when pushing the Sample Pin Actuator over the Sample Ejector Pin that the Sample Ejector Pin is not pushed back down the Capture Tube. Tighten M5 * 25 cap head screws to specified torque setting. Fit the two halves of the Split Collet (30) to the Sample Tube. Push the Split Collet down into the recess in the top of the Sample Ejector Pin Actuator. ENSURE ALL ORIGINAL SHIMS ARE REFITTED UNDER SPLIT COLLET. If this is not done, the Sample Ejector Pin may strike the Sample Head Pillar (81) when the Sampler is operated and result in damage. Fit 'O' Ring (36) to Piston. Liberally grease the bore of the Bottom Housing (18) and the Capture Tube/Piston Assembly. Slide the assembly through the Bottom Housing into the Graphite Seals (70). Carefully push through the seal and slide assembly fully home into the Bottom Housing Reassembly of Top Housing Note: The Lock Ring (32) on top of the Actuator must not be disturbed. If the Bush (20) is moved, the grab size of the Sampler will be altered. Fit the 2 off 'O' Rings (38) in the bore of the Sealing Bush (20). Fit 'O' Ring (35) in the Top Housing (16). Liberally grease the internal surface of the Sealing Bush (20), the outside of the Sample Pin Actuator (25) and the internal bore of the Top and Bottom Housings. Slide the Top Housing over the Sample Pin Actuator and carefully push the assembly through the Balseal until the Top and Bottom Housings are together. Rotate the Top Housing to align the Actuator Ports. Fit 6 off M8 * 35 cap head screws and tighten to specified torque. Apply slight air pressure to the port in the Bottom Housing to move the Piston assembly upwards, whilst holding the Sample Ejector Pin down in the Sample Pin Actuator to prevent it moving independently of the Sample Pin Actuator. Place new M6 Washer (33) on top of Sample Tube Actuator. Screw Sample Ejector Head (28) onto Sample Pin Actuator and, using a 19mm A/F open ended spanner to hold the Sample Tube Actuator (16), tighten the Sample Tube Head using the C Spanner, Special Tool A and a soft-faced hammer. Note: This is a pressure-retaining joint and must be tight refer to torque settings. Fit new Spring (41), and Split Collet (30) under the Sample Ejector Head. Fit new Gaiter (47) over the assembly and secure with a cable tie. 8.8 Reassembly of Actuator and Bottom Plug Sub-Assemblies to Main Body

13 Slowly push the Piston down to the bottom of its stroke, using air pressure to the port in the Upper Actuator Housing, ensuring the Capture Tube passes over but does not strike the Sample Head Pillar. If necessary, adjust the Copper Washers between the Sample Head Pillar and the Main Body. Tighten the Bottom Plug using the C Spanner, Tool A. Tighten the Gland Nut (69) until the Graphite Seal starts to tighten on the Capture Tube. 9 Fault Diagnosis See Section 7 for details of any overhaul required. 9.1 Sampler Does Not Operate Check that all air and electrical connections are secure and correct. Check that the air pressure, indicated on the regulator pressure gauge, is correct (refer to project P&ID). Adjust the regulator if necessary. If the air pressure supplied to the regulator is too low, check the air supply. Ensure that the electrical pulse signal supplied to the Solenoid Valve is the correct duration (500 milliseconds). Check that this signal operates the Solenoid Valve. If the Sample Ejector Head moves only slightly, the sample outlet is obstructed. Check that the sample line to the sample receiver is not blocked. A blockage may have formed within the sampler. 9.2 Sampler Operates But Does Not Produce a Sample Ensure that there is fluid in the bypass loop. Ensure the air pressure is correct. If the air pressure is too low, the actuator will not stroke fully. Check the stroke of the actuator is correct - the Sample Ejector Head should move approximately 9mm. Check that the Solenoid Valve is energised for 500 milliseconds second each cycle, short cycling will prevent the actuator from stroking fully. Failure of either the Check Valve (fitted to the Bottom Plug) will cause a reduction or loss of sample grab volume. 9.3 Air Leaks from Actuator Air will leak from the Actuator between the Top and Bottom Housings if the "O" Ring fitted to the Top Housing is damaged. Air will leak from the Actuator between the Sample Pin Actuator and the Sealing Bush if the "O" rings (69) are worn or damaged. Air will leak from the actuator between the Top Housing and Sealing Bush if "O" Ring (21) is damaged. Air will leak from the actuator between the Sample Pin Actuator and the Sample Ejector Head if the "O" Ring (38) is damaged. Air will leak from the Actuator between the Bottom Housing and the Lower Piston Rod (via the drain port) if Quadring (37) is worn or damaged. Air will leak from the drain hole in the Lower Piston Rod (via the drain port) under one or more of the following conditions:

14 a) The "O" ring (26) fitted to the seal ring in the lower piston rod is worn or damaged. b) The Seal Nut (29) fitted to the Lower Piston Rod is not properly tightened. c) The mating face of the Seal Ring (31) and/or the Lower Piston Rod is damaged and does not seal properly. Dismantle the actuator and inspect the "O" Rings. If the "O" Rings are worn or damaged, replacement "O" Rings must be fitted. 9.4 Process Fluid Leaks The following sections relate to failures that may be difficult to observe without disassembling the probe. Fluid will leak from between the main body and the Seal Gland if the Copper Washer (75) is damaged or seating incorrectly. Fluid will leak from between the Capture Tube and the Gland Nut if the Graphite Seal (70) is worn or damaged. Tighten the Gland Nut (69), or if leak persists, remove and inspect the Graphite Seal. If the seal is worn or damaged, a replacement seal must be fitted. Fluid will leak from between the Bottom Plug and the Main Body if the copper washers (75) are damaged. Dismantle the Bottom Plug Assembly and inspect this item. All copper washers must be replaced when reassembled. 10 Drawings and Parts Lists Drawing No Parts List No Title B Group 4 Hi-Temp Sampler 4 150lb R.F Special Tools 3714 Item 12 Recommended Spares List C19440 D26465 Installation Drawing Ancillaries plate 11 Disclaimer Whilst Jiskoot Autocontrol Limited has taken every care in the preparation of this document, it cannot accept responsibility for printing errors or omissions and does not warrant that it is correct and comprehensive in every particular. Equipment supplied should always be operated by persons with an appropriate level of skill and training. Jiskoot Autocontrol Limited shall not be liable for incidental or consequential damages resulting from the furnishing, performance or use of this material. Jiskoot Autocontrol pursue a policy of continuous improvement, and information given herein may be updated without notice. Further, this information is proprietary to Jiskoot Autocontrol Limited, and must not be disclosed to any third party except as may be required to operate the equipment supplied in accordance with the purposes for which it was sold by the persons properly licensed to operate it.

15 Notes

16 Notes

17 Notes DEF Tunbridge Wells, Kent, TN1 2DJ, UK Tel +44 (0) , Fax +44 (0) DEF Houston, TX77014, USA Tel , Fax