installation, operation & maintenance manual for … 2in mkiii... · h33 issue 0 abc...

H33 Issue 0

abc INSTALLATION, OPERATION & MAINTENANCE MANUAL

FOR

210 MKIII (2”) CELL 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.).

Truly representative sampling of crude oils etc., cannot be achieved by one single product in isolation. A well designed system and operating procedures as laid down in the Sampling Standards ISO 3171, API 8.2 and IP Chapter VI section 2 are mandatory.

Please consult Jiskoot for further information and assistance.

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 Ltd. 2007 Jiskoot Ltd. All rights reserved. Jiskoot Ltd., formerly Jiskoot Autocontrol Ltd., also trades as “Jiskoot” and “ Jiskoot In

210 2” MkIII Cell Sampler

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defTABLE OF CONTENTS

1 WARRANTY ................................................................................................................................................ 4

2 INTRODUCTION ........................................................................................................................................ 4

3 OPERATING INSTRUCTIONS................................................................................................................. 5

4 GLOSSARY OF SPECIAL TERMS .......................................................................................................... 6

5 UTILITIES REFERENCE .......................................................................................................................... 6

6 FULL FUNCTIONAL DESCRIPTION ..................................................................................................... 6

7 GENERAL ASSEMBLY & BILL OF MATERIAL ................................................................................. 8

8 INSTALLATION DETAILS ..................................................................................................................... 10

9 MAINTENANCE AND TROUBLESHOOTING.................................................................................... 12

9.1 HEALTH AND SAFETY PRECAUTIONS ..................................................................................................... 12 9.2 WEEKLY MAINTENANCE ........................................................................................................................ 12 9.3 ANNUAL MAINTENANCE (OR AS DETERMINED BY SITE CONDITIONS) ..................................................... 12 9.4 OVERHAUL INSTRUCTIONS .................................................................................................................... 12 9.5 TORQUE SETTINGS................................................................................................................................. 13 9.6 BOTTOM PLUG SUB-ASSEMBLY ............................................................................................................ 14 9.7 ACTUATOR SUB-ASSEMBLY .................................................................................................................. 15 9.8 REASSEMBLY OF SAMPLE TUBE HEAD .................................................................................................. 22 9.9 REASSEMBLY PLUG TO MAIN BODY...................................................................................................... 22 9.10 TESTING ................................................................................................................................................ 22

10 FREQUENTLY ASKED QUESTIONS................................................................................................ 23

10.1 SAMPLER DOES NOT OPERATE .............................................................................................................. 23 10.2 SAMPLER OPERATES BUT DOES NOT PRODUCE A SAMPLE ................................................................... 23 10.3 SAMPLER FAILS TO TAKE ADEQUATE SAMPLE........................................................................................ 24 10.4 SAMPLER TAKES EXCESSIVE SAMPLE..................................................................................................... 24 10.5 LEAKS FROM ACTUATOR ...................................................................................................................... 24 10.6 PROCESS FLUID LEAKS .......................................................................................................................... 25 10.7 VIBRATION ............................................................................................................................................ 25

11 SUB SUPPLIER INFORMATION ....................................................................................................... 25

12 RECOMMENDED SPARES LIST....................................................................................................... 25

12.1 SERIES 210, EH & EH-HP CELL SAMPLER SPARE PARTS...................................................................... 25 12.2 SERIES 210 HP CELL SAMPLER SPARE PARTS ....................................................................................... 27 12.3 ALTERNATIVE SEALS FOR MTBE & SIMILAR APPLICATIONS................................................................ 27 12.4 SPECIAL TOOLS ..................................................................................................................................... 27 12.5 ANCILLARY EQUIPMENT........................................................................................................................ 27

13 PRODUCT SPECIFIC DRAWINGS.................................................................................................... 28

14 2CC CELL SAMPLER .......................................................................................................................... 28

15 DISCLAIMER ........................................................................................................................................ 28


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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)1892 518000 or [email protected], 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

Figure 1 - Series 210 Mk III 2” Cell Sampler.


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defThe 2” 210 Cell Sampler range provides a means of extracting a sample from liquids flowing through a nominal 2” pipeline or bypass. Primarily designed for applications where air pressure is available to provide the motive power, the 210 2” Cell Sampler is normally installed into a 2" bypass loop taken off the main pipeline. A hydraulically operated version is together with a Hydraulic Power Pack is available for installations with no air supply.

The Jiskoot Series 210 2” Cell Sampler is designed to extract nominal 1cc samples from products ranging from crude oil, refined hydrocarbons (including non-lubricating products) and non-corrosive chemicals, operating in a pressure range from 3 to 100 Barg, within a product temperature range of -20 to 100oC, (Option for a high temperature kit providing a range up to 200oC, is available) on viscosities 0.5 to 5000cSt in an ambient temperature range of -20oC to 40oC. Versions giving a 2cc sample size and conversion kits to change existing samplers to the larger sample size are available to meet specific site requirements (refer to Section 14, Addenda - 2cc Sampler).

The performance and seal life of the 210 2” Cell Sampler is dependent on the process pressure, viscosity and outlet configuration which includes the tubing, valves, and sample collection pressure in the sample receivers. Consult Jiskoot for optimal configuration.

The cell sampler/bypass configuration allows the sampler to be located at the convenience of the user rather than restricted by the position of the off take in the main pipeline. It provides the facility of easy isolation for maintenance and extremely low internal (retained) volume. The flow rate through the cell sampler/bypass loop will be crucial to ensuring accuracy (see installation)

The Sampler incorporates features to minimise and simplify maintenance as well as providing integrity against leakage under most likely circumstances.

The 2” 210 Cell Sampler is designed for installation between a mating pair of either 2" 150#, 300#, 600#, 900# and 1500# RTJ or raised face flanges. Tested to full static flange rating pressure.

Other flanging standards may be available to special order and spool mounting length.

The 2” 210 Cell Sampler is supplied with three actuator options. These are:

210 Standard air actuated Cell Sampler (For line pressures less than 600#)

210 HP Air actuated Cell Sampler for high-pressure (ANSI 900#) applications or where there is low air pressure (<5 Barg)

210 EH 210 Cell Sampler fitted with Electro-Hydraulic actuator.

Note: When requesting assistance or spare parts, pl ease provide the Cell Sampler Model and Serial Numbers to ensure that the correct options are quoted.

3 Operating Instructions The 2” 210 Cell Sampler must be installed in accordance with the “Installation Details”, and be connected to a suitable sample collection system.

To operate the Sampler, it requires a regulated air supply at 5 - 8 Barg (70 - 120 psig) and a signal to energise the external Sampler Solenoid, which in-turn actuates the sampler at the required intervals. Any pipeline conditioning facility must be active to ensure a representative product is available to the Sampler. Electro-Hydraulic versions (2” 210 EH) require a Hydraulic Power Pack to provide the pressure source.

Control of the Sampler, including changeover of Sample Receivers will be determined by the type of Sampler Control System being used.


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4 Glossary of Special Terms Grab: The action of taking an individual sample (normally 1 or 2 ml) from the pipeline.

5 Utilities Reference Air Supply – (Pneumatic samplers only) 4 - 10 Barg (40 - 145 psig)

2” 210 standard Cell Sampler

0.8 m3/hr or 0.47 scfm (5 Barg at 30 grabs/min)

Air Consumption

210 HP Cell Sampler 1.67 m3/hr or 1.0 scfm (5 Barg at 30 grabs/min)

AC 100-254 Volts 50/60 Hz DC 24 Volts DC

Solenoid Voltages Available:

Power Consumption 10 Watts Pneumatically 250 milliseconds Solenoid energisation time 210 EH Cell Sampler 500 milliseconds 210 standard Cell Sampler

100 Samples/min

210 HP Cell Sampler 50 Samples/min 210 EH Cell Sampler 30 Samples/min

Maximum Sampling Rates*

210 EH-HP Cell Sampler

15 Samples/min

6 Full Functional Description

Figure 2 - 210 Cell Sampler 3 step operation.

The 2” 210 Cell Sampler operates on Jiskoot’s standard 3-step principle, using an air or hydraulically actuated piston to provide the motive power.

In the idle, or de-energised state, air pressure is applied to the bottom of the Actuator Housing through Port 'B', holding the Capture Tube and the Sample Tube at the top of their stroke, allowing process product to flow through the Cell Sampler Body Fig.2 (Left).


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defWhen the external Sampler Solenoid is energised, it applies air pressure to Port 'A', forcing the piston down. Pressure from the underside of the piston is naturally vented through the valve to atmosphere. The downward movement of the combined piston and capture tube pass over the Lower Capture Tube Seal, trapping a nominal 1 or 2cc of sample of product Fig. 2 (Middle).

The third step is accomplished as the continued downward motion collects and pulls the catchplate, drawing the Sample Tube along with the Capture Tube downward. The captured sample compresses the Check Valve and spring and ejects through the centre of the Bottom Plug, to the sample receptacle. Fig. 2 (Right).

When the Sampler Solenoid is de-energised, air is vented from the top of the Actuator Housing and applied to the underside of the Piston, moving the Capture Tube and Sample Tube back to their start position. The spring returns the Check Valve with any vacuum being relieved via a Breaker, incorporated in the Sample Tube.

Product continues to pass through the Cell Body and the Sampler is ready for the next grab to be initiated.


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7 General Assembly & Bill Of Material Reference Master Drawing C16213


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defReference Master Drawing C29176

Figure 3 - 2” 210 MkIII Cell Sampler


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Figure 4 - Electro-hydraulic (EH) Actuator Components

8 Installation Details

Electrically operated 5 port

Solenoid Valve

FLOWFLOWFLOWFLOW

ChangeChangeChangeChange----over Valve for over Valve for over Valve for over Valve for

Sample ReceiversSample ReceiversSample ReceiversSample Receivers

OverOverOverOver----pressure pressure pressure pressure Relief ValveRelief ValveRelief ValveRelief Valve

Setting dependant upon Sample Receiver System

DrainDrainDrainDrain

InInInIn----line Check Valveline Check Valveline Check Valveline Check ValveSet to 5 Bar above Line

Pressure

Line Balance Relief Line Balance Relief Line Balance Relief Line Balance Relief ValveValveValveValve

(used as alternative to In-line Check Valve)

Line Line Line Line PressurePressurePressurePressure

Sample Sample Sample Sample OutletOutletOutletOutlet

Sample Sample Sample Sample InletInletInletInlet

Customer Pulse Signal to Sampler

Customer Air

(4-7 Bar)

Sample Pulse>=250ms

Pulse Length>7600ms (Standard)

>1300ms (High Pressure/Hydraulic)

¼" NPT Air Connections

¼" NPT Vent(Do not plug)

Port "A"

Port "B"

The 2” 210 Cell Sampler is designed to be bolted between a pair of matting 2" ANSI 150#, ANSI 300#RF or ANSI 600#RF flanges and can withstand static pressure testing to full flange rating. Alternative flange sizes and finishes may be supplied to suit specific applications. The axis of the outlet pipe connection should be horizontal or downward facing to prevent water traps. It is crucial that the flow through the bypass loop and cell sampler is adequately mixed in regard to the properties of interest. Where sampling for water content we would normally recommend that a minimum flow velocity within the cell sampler and for 1 metre upstream exceed 3.5 m/s (6 m3/h).

A Sampler Solenoid Valve must be selected to suit the specific application and will require connecting to suitable supplies via glands and cables appropriate to the area classification.

Note: The correct rating fuse must be included in t he Solenoid Valve supply circuit.


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defA regulated air supply must be connected to the Solenoid and the normally energised outlet connected to Port 'B' of the Sampler. The normally de-energised port of the Solenoid must be connected to Port 'A'. The exhaust port(s) of the Solenoid may be piped away or fitted with silencers as required. (On Electro-Hydraulic applications, the Solenoid is incorporated into the Hydraulic Power Pack.)

If required, the bottom port (drain cavity) of the Actuator may be connected to a closed drain or a pressure switch.

The ¼" Swagelok Sample Outlet Port situation in the Bottom housing must be connected to the Sample Receiver System using ¼" or 6mm stainless steel tubing via either an in-line Check Valve or a Jiskoot Line Balanced Relief Valve and a relief valve as shown in the above diagram.

Note: Failure to fit an external check valve may re sult in the Sampler continually discharging product from the outlet due to the line pressure exceeding the internal check valve setting.

The Check Valve will normally be set to 5 Bar above the maximum line pressure, ensuring that this is sufficient to allow for any additional pressure increase created by thermal expansion when in the event of isolating valves being closed together with any effects trace heating and or solar energy may have. If the cracking pressure is set too low, the valve may open under adverse conditions, causing the Sample Receiver System to overfill and the sample to leak through the relief valve to atmosphere.

Where line-balanced, high-pressure sample receivers are being used (i.e. where the sample is being collected at, or close to line pressure), we would recommend the installation uses the Swagelok R3A or any similar valves unaffected by back pressure, to avoid placing unnecessary load on the Sampler seals; with the Check Valve being be set to operate at 1 Bar. If the valve is found to lift and fill the Sample Receiver due to pressure surges, this setting may be increased slightly.

The relief valve fitted to the sample line is to provide protection to the Sampler in the event of the sampler being operated against a blocked sample line, e.g. without a sample receiver being fitted or with a full sample receiver. This relief valve should be within the maximum pressure rating of the receiver system, but may need to be increased slightly to allow for momentary pressure surges as the sample is being taken.

Ensure that lengths of tubing connecting the sampler to the receiver system are kept to a minimum to minimise "dead" i.e. trapped volume (long lengths of tubing also create extra back pressure and premature seal wear), and that the sample travels downhill at a minimum angle of 15 degrees from the Sampler Outlet to the Receiver to avoid water traps. In the sample line is external, the sample outlet piping may require heat tracing to prevent blockage.

The Sampler Control System must be capable of supplying a pulse of a minimum 250 milliseconds duration to the Sampler Solenoid Valve to ensure that there is sufficient time for the Sampler to complete a full stroke at each actuation (in most systems using air 500milliseconds is normal). The Actuator should dwell momentarily at the bottom of its travel before the Solenoid is de-energised and the Sampler returns to its 'rest' state.


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9 Maintenance and Troubleshooting 9.1 Health and Safety precautions

The 2” 210 MkIII Cell Sampler may be used in applications involving 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.

9.2 Weekly maintenance

Regular maintenance is limited to draining excess moisture from the air filter/regulator or on EH applications, checking the level in the hydraulic oil reservoir on the Hydraulic Power Pack.

9.3 Annual maintenance (or as determined by site co nditions)

The 2” 210 MkIII Cell Sampler is designed to operate continuously for a period of about 1,000,000 grabs or 12 months before a major overhaul, however this service interval will be affected by the type of product being sampled, particularly the amount of particulate matter such as sand, and therefore can not be guaranteed. When used in crude oils with high levels of sediment or from mixed carrier shipments, the maintenance interval may be shortened. 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.

PLEASE NOTE : THE 210 2” MKIII CELL SAMPLER HAS A “ BOLT ON” BOTTOM PLUG AND A BOLT ON “CELL BODY ADAPTER”. ANY MAINTENANCE REQUIRING REMOVAL OR ADJUSTMENT SHOULD ONLY BE CONDUCTED BY C OMPETENT AND TRAINED STAFF.

It is essential that work involving the use of clamps or vices, allow for soft vice to prevent damage, particularly those with sealing faces. All components must be thoroughly cleaned of dirt and other contamination by degreasing and drying prior to re-assembly.

A Special Tool Kit, Part No 45-0127-00, is 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.

9.4 Overhaul Instructions

The instructions for strip down and reassembly are for the standard version of the 2” MkIII Cell Sampler, but are applicable to all variants, as the main differences between the standard pneumatically operated Sampler, EH Samplers and HP Samplers are in the Actuator assembly.

Upon satisfactory re-assembly; hydraulically actuated (EH) Cell Samplers may be tested using compressed air or gas instead of hydraulic oil where this is more convenient.

See Section 12 for details of Spares Kits and the Special Tools required to overhaul all versions of the Cell Sampler.

Separate details are given for overhaul of individual sub-assemblies and replacement of the Sample Tube Seal.


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defThe complete overhaul should be carried out in the following order:

Step Description

1 Removal and overhaul of the Bottom Plug Sub-Assembly

2 Removal and overhaul of the Actuator Sub-Assembly

3 Overhaul of the Main Body

4 Reassembly of the Actuator and Bottom Plug Sub-Assemblies to Main Body

NOTE: It is essential that soft vice jaws are used whenever components are required to be held, and th at all components, particularly those with sealing fac es are thoroughly cleaned of dirt and other contamination by degreasing and drying prior to reassembly. If any of the sliding surfaces are damaged, leakage will occur from the seals.

All joints, 'O' Rings and moving parts must be lub ricated on assembly using a general purpose grease such as Castrol “Spheerol B2” grease or an e quivalent lithium based water-resistant grease.

Jiskoot recommend that to prevent seizure, all scr ewed components are lubricated with copper grease on assembly.

9.5 Torque Settings

The following torque settings should be used in the reassembly of the sampler:

Screw Location Size Torque

Bottom Actuator Housing to Adaptor Ring

M8 Cap Head (99-0025),(99-0033-00)

25Nm/18.4lbfft

Lower Piston Rod to Capture Tube (36-1186-00) 75Nm/55.3lbfft

Sample Tube Actuator to Catchplate

M5 Cap Head (99-0027-00), (99-0015-00)

10Nm/7.4lbfft

Actuator Top to Bottom Housing M8 * 30mm Cap Head (99-0030-00)

25Nm/18.4lbfft

“Cell Body Adaptor” (36-3303-00) to Cell

M8 * 20mm Cap Head 25Nm/18.4lbfft

Bottom Plug M6 * 20mm Cap Head (99-0041-00)

15Nm/11lbfft

Sample Tube Head to Sample Tube Actuator 60Nm/44.5lbfft


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def9.6 Bottom Plug Sub-Assembly

Figure 5 - Bottom Plug Assembly

It is not necessary to completely remove the bottom plug unless there is an evident leakage; however depending on the service interval it is recommended, so that all seals are replaced due to potential hardening of the materials.

Using the appropriate ‘C’ Spanner, unscrew the locking ring (13) and remove the “Adjuster Plug” (12). Using the appropriate “Allen key” unbolt the Bottom Plug (14) from the bottom of the main body.

Unscrew and remove the Sample Outlet Connector (11) complete with the Dowty seal. Remove the Spring (10), Check Valve Stem and Valve Tip (9).

Replace the Valve Tip with a twisting motion to screw it in.

Remove the 'O' Rings (8 and 15), toughly clean the “O” ring grooves and bodies, before re-fitting with greased 'O' Rings.

Remove the Seal (17) from the Adjuster Plug. Check for wear, replacing if necessary.


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defWarm the new Seal (17) in hot water. Place the Seal over the Seal Loading Mandrel, Special Tool ‘G’ and push down approximately half the mandrel's length to expand the lip seal so it will fit over the Bottom Plug.

Remove Seal from Mandrel and fit to Bottom Plug ensuring the Seal is fitted with the seal spring toward the head of the Bottom Plug.

Using fingers, reform the Seal into the groove and then place Seal Assembly Tool, Special Tool ‘J’ over the Bottom Plug (tapered end first) to set the Seal to the required size. Leave for 3-5 minutes.

Remove Seal Sizing Tool and check Seal for damage.

Re-assemble the Check Valve and Valve Tip to the Adjuster plug, replace with new spring (10) and Dowty washer before re-screwing the Sample Outlet Connector.

9.7 Actuator Sub-Assembly

Figure 6 - Actuator Sub-Assembly


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9.7.1 Removal of Sample Tube Head

Remove the Gaiter to expose the Spring and actuator.

Hold the Sample Tube Actuator with a 19mm (3/4”) A/F open-ended spanner, and using a suitable ‘C’ Spanner, loosen the Sample Tube Head. Remove the Sample Tube Head, Collet and Spring.

9.7.2 Removal of Actuator Top

Remove the six M8 screws attaching the Top Actuator Housing.

Remove the top housing complete with Sealing Bush, Locking Ring.

Note: The Lock Ring on top of the Actuator must not be disturbed. If the Bush is moved, the grab size of the Sampler will be altered.

Remove and replace “O” ring after cleaning and re-greasing

9.7.3 Removal of Piston and Sample Tube Assembly

Remove the complete Piston and Sample Tube Assembly


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def9.7.4 Removal of Actuator and Adaptor Ring

Note the location of the Lower Actuator in order that the ports will face in the original direction on reassembly.

Remove the M8 cap head screws, situated under the retaining Adaptor Ring, exposing the bolted adaptor.

Remove and replace the Seal, re-assemble the Adaptor Ring and re-tighten with new cap head screws to the specified torque. Re-assemble the lower actuator body noting ports original location. Tighten with new cap screws.

9.7.5 Overhaul of Piston/Sample Tube Actuator/ Lower Piston Rod Assembly

Holding the Lower Piston Rod in a protected soft jaw. Use a suitable rod of soft material e.g. Delrin; push the bottom end of the Sample Tube approximately 20mm up inside the Capture Tube.

This will expose the Split Collets at the opposite end of the Sample Tube.

Remove the two halves of the Split Collet and any Shims fitted underneath it. Retain Shims for reassembly.


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defRemove the six M5 screws, releasing the two halves of the Catchplate and Piston from the Lower Piston Rod.

Remove the Catchplate and Piston.

Remove the Sample Tube Actuator from the Sample Tube, replacing the internal “O” ring.

Using Nut Peg Spanner, Tool ‘E’. Unscrew and remove the Seal Nut from the Lower Piston Rod.

Remove the Sample tube by pushing the top end of the Sample Tube down, remove and discard the seal and Slydring.

Remove the Seals, Seal Ring, and “O” ring from the Lower Piston Rod.


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defUse a screwdriver in the M3 cheese head, rotate and depress the Vacuum Breaker Stem so that the hole in the Sample Tube aligns with the hole in the Vacuum Breaker Stem.

Use a 1.5mm drill through the holes to hold the assembly whist unscrewing and removing the M3 Screw, Star Washer and Spring.

Remove the 1.5mm drill from the Sample Tube and withdraw the Vacuum Breaker Stem/Valve Assembly through the bottom of the Sample Tube. Remove the 'O' Ring from the Vacuum Breaker Valve.

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 comp lete sub-assembly (part no 36-5000-00, including th e Lower Piston Rod must be obtained from Jiskoot.

Re-assemble as a reversal, all parts being cleaned, inspected and freshly greased to aid assembly. Re-assembly should ONLY be conducted by competent trained personnel. Re-assembly should ideally be in a clean environment, with reference to direction of sealing faces and re-alignment of actuator.


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defPlease note :

Fit 'O' Ring (Part No. 37-0709-00) supplied in the Spares Kit, to the Sample Tube Collet groove to prevent damaging the Seal as it is pushed over the groove.

(Colour used to illustrate position ONLY)

Fit the new Seal onto the Sample Tube from the top. Ensure that the Seal is fitted with the seal spring downwards, as indicated.

Remove and discard the 'O' Ring (Part No. 37-0709-00)

Insert the Sample Tube into the Lower Piston Rod/Capture Tube Assembly, grease and carefully position the new seal in the seal recess. Using Assembly Tool, Special Tool ‘L’, push the seal into position.

Fit ‘O’ Ring, Seal Ring, Seal, and Seal Nut and tighten using Nut Peg Spanner - Tool ‘E’.


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def9.7.6 Reassembly of Piston/Catch Plate/Actuator Ass embly

Re-Fit Piston and piston “O” ring to Lower Piston Rod with new cap screws, ensuring Piston is correct way round.

Fit new 'O' Ring to bore of the

Sample Tube Actuator.

Re-fit Sample Tube Actuator and Catchplate Assembly to the Piston Rod Assembly using new cap head screws, tighten to specified torque.

Note: Care must be taken when pushing the Sample Tu be Actuator over the Sample Tube that the Sample Tube is not pushed back down the Capture Tube.

Tighten M5 * 20 cap head screws (33) to specified torque setting.

Re-fit the Split Collet to the Sample Tube. Push the Split Collet down into the recess in the top of the Sample Tube Actuator. ENSURE ALL ORIGINAL SHIMS ARE REFITTED UNDER THE SPLIT COLLET. Potential damage may occur If this is not set as original.

Note: EH Samplers have two 'O' Rings fitted to the Piston and an 'O' Ring sealing Liner fitted to the Actuator Bore.

9.7.7 Lower Sample Tube Seal

As previous in section 4, warm the Seal in hot water. Place the Seal over the Seal Loading Mandrel, Special Tool ‘G’ and push down approximately half the mandrel's length to expand the lip seal so it will fit over the Sample Tube.

Transfer the Seal from the mandrel and fit to Sample Tube ensuring the Seal is fitted with the seal spring facing towards the end of the Sample Tube.

Using fingers, reform the Seal into the groove and then place Seal Assembly Tool, Special Tool ‘J’ over the End Plug (tapered end first) to set the Seal to the required size. Leave for 3-5 minutes. Remove Seal Sizing Tool and check Seal for damage. Fit the new Slydring by wrapping it round its groove in the Sample Tube until it’s diagonally cut ends meet.


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def9.7.8 Reassembly of Piston and Sample Tube Assembly

Confirm replacement of 'O' Rings in the bore of the Sealing Bush and the Top Housing.

Liberally grease the internal surface of the Sealing Bush, the Sample Tube Actuator and the internal bore of the Top and Bottom Housings.

Slide the Piston and Sample Tube Assembly into the lower actuator body, followed by replacing the complete top housing, aligning the Actuator Ports.

Fit 6 off M8 * 35 cap head screws and tighten to specified torque.

9.8 Reassembly of Sample Tube Head

Renew the Gaiter and Spring. Hold the Sample Tube Actuator with a 19mm (3/4”) A/F open-ended spanner, and using a suitable ‘C’ Spanner, tighten the Sample Tube Head.

Replace the Sample Tube Head Collet and allow the spring to seat, form the gaiter back to cover the spring and tube head. Secure the gaiter with a cable tie.

9.9 Reassembly Plug to Main Body

Ensure the piston is at its lowest point, re-fit and secure the Bottom Plug to the bottom of the main body, using the appropriate “Allen key”.

Rotate the “Adjuster Plug”, until the adjustment can be felt touching the capture tube. Unscrew or “backoff” the adjuster plug by half a revolution.

Using the appropriate ‘C’ Spanner, tighten the locking ring.

9.10 Testing

It is recommended that where a test facility is available, the Sampler is pressure tested and re-calibrated prior to returning to service.


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10 Frequently Asked Questions 10.1 Sampler Does Not Operate

Check that all Actuator and electrical connections are secure and correct.

Check that the Actuator pressure, indicated on the air regulator or Hydraulic Power Pack discharge pressure gauge is between 5-6 Barg, re-adjust as required.

Ensure that the electrical pulse signal supplied to the Solenoid Valve is the correct duration (500 millisecond minimum for air, 1 second minimum for hydraulic applications).

If the Sample Tube Head moves slightly, the sample outlet is obstructed. Check that the line to the Sample Receiver is not blocked.

A blockage may have formed within the Cell Sampler.

10.2 Sampler Operates But Does Not Produce A Sample

Check all valves are open and that there is fluid in the pipeline.

Check Sampler Controller is demanding a grab and that any interposing relays are operating satisfactorily.

Is solenoid being energised? - Check Solenoid Fuse and operate manually where solenoid has manual override facility.

Check that the Solenoid Valve is energised for minimum of 0.5-1.0 second each cycle. Short cycling will prevent the Actuator from stroking fully.

Check that Sample Receiver is not either full, blocked by wax or isolated (Carefully loosen ¼" connections in sample discharge tubing to test).

Ensure the Actuator pressure is correct. If the pressure is too low, the Actuator will not stroke fully. Check the stroke of the Actuator is correct - the Sample Tube Head should move approximately 9mm.

Failure of the Lower Capture Tube Seal, the Vacuum Breaker 'O' Ring, or the Check Valve will cause a reduction or loss of sample grab volume. The following test may be carried out to ensure that they are sealing correctly:

NOTE: Prior to performing this test, ensure that the Sampler is full of fluid by rapidly operating the Sampler (30 cycles).

IMPORTANT: THIS TEST MUST BE CARRIED OUT WITH GREAT CARE BECAUSE THE SAMPLER IS CAPABLE OF DEVELOPING VERY HIGH SAMPLE DISCHARGE PRESSURES.

Connect a pressure gauge (0 to 400 Bar/6000 psi) to the Sample Outlet Port of the Sampler. It is recommended that a hydraulic hose is used to connect the pressure gauge. This will act as a hydraulic accumulator to dampen the pressure pulse as each sample grab is ejected.

Operate the Sampler ONE GRAB AT A TIME by manually closing the Sample Solenoid relay contacts in the safe area (some systems have a manual override on the actuating solenoid). Each time the Sampler is operated, a pressure increase (approx. 21 Bar/300 psi) should be produced as the pressure of the isolated sample grab is raised to force it through the Check Valve. After a small number of operations, the Sampler should be capable of generating a sample pressure of 140 Bar/2000 psi. This will only occur if the Capture Tube Seal and Vacuum Breaker are sealing correctly.

Stop operating the Sampler once the sample discharge pressure has reached 140 Bar/2000 psi.


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defThe pressure shown on the pressure gauge should be maintained. This will only occur if the Check Valve is sealing correctly. The pressure will drop if the Check Valve is leaking. If the pressure only drops very slowly (say 10% in 5 minutes or in maximum interval between grabs if longer), this indicates a very small leak through the Check Valve which should not affect the sample grab volume of the Sampler

10.3 Sampler fails to take adequate sample

Check Sample Receiver is not full or the sample outlet piping blocked through waxing.

Check the external Check Valve fitted to Sampler Outlet Adapter is set to 5 Bar above line pressure for normal low-pressure receiver systems and to 1 Bar where high-pressure sample receivers are being used. If pressure is too high, excessive wear will be caused to the Sampler internal seals.

Check that the relief valve fitted to the sample discharge lines is not passing.

Ensure that the Sampler Controller is not either demanding too fast a sample grab rate (120 grabs per minute maximum), or that the signal to the solenoid is too short and not allowing the Actuator to travel to the full extent of its stroke.

Check that the air supply is at the correct pressure and capacity to operate the Cell Sampler (Refer to Utilities Section).

If the above are satisfactory, than the Sampler will require a change of internal seals.

10.4 Sampler takes excessive sample

Check the External Check/Relief Valve fitted to Sampler Outlet Adapter is set to 5 Bar above line pressure for normal low-pressure receiver systems and to 1 Bar where high-pressure sample receivers are being used. If pressure is too low, then the internal Check Valve may be lifting allowing sample to pass at all times.

If the above are satisfactory, than the Sampler will require a change of internal seals.

10.5 Leaks From Actuator

Leaks will occur from the Actuator between the Top and Bottom Housings if the 'O' Ring (26) fitted to the Top Housing is damaged.

Leaks from the Actuator between the Sample Tube Actuator and the Grab Size Adjustment Bush indicate the 'O' Rings are worn or damaged.

If the 'O' Ring is damaged the Actuator will leak between the Top Housing and Grab Size Adjustment Bush.

Leaks from the Actuator between the Sample Tube Actuator and the Sample Tube Head indicate the 'O' Ring is damaged.

Air/hydraulic oil leaks will occur from between the Bottom Housing and the Lower Piston Rod (via the drain port) if Quadring is worn or damaged.

Air/hydraulic oil will leak from the drain hole in the Bottom Housing (via the drain port) under one or more of the following conditions:

The 'O' Ring fitted between the Seal Ring and the Lower Piston Rod is worn or damaged.

The Seal Nut fitted to the Lower Piston Rod is not properly tightened.

The mating face of the Seal Ring and/or the Lower Piston Rod is damaged and does not seal properly.

Dismantle the Actuator (see Section 9.2) and inspect the 'O' Rings. If the 'O' rings are worn or damaged, replacement 'O' Rings must be fitted.


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def10.6 Process Fluid Leaks

The Series 210 Cell Sampler has been designed so that any seal failures will result in flow from the drain port in the Actuator. The following failure may be difficult to observe without dismantling the Cell Sampler.

Fluid will leak from the drain hole in the Lower Piston Rod if both the Lower Sample Tube Seal and the Seal fitted to the Lower Piston Rod are worn or damaged.

10.7 Vibration

Vibration is unlikely to occur in cell samplers.

11 Sub Supplier Information The following sub supplied items are used in the 210 Cell Sampler:

♦ Sampler Solenoid Valve (selected to suit application specific hazardous area requirements and power supply).

♦ Air regulator.

Neither of the above contains any user serviceable parts.

Hydraulic Power Pack (EH versions) - refer to Hydraulic Power Pack Handbook.

12 Recommended Spares List When requesting assistance or spare parts, please advise the Sampler Model and Serial Numbers to ensure that the correct options are supplied.

12.1 Series 210, EH & EH-HP Cell Sampler Spare Part s

Spare Parts Kit (45-0124-00)


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def12.2 Series 210 HP Cell Sampler Spare Parts

HP Cell Sampler Spare Parts Kit (45-0176-00)

12.3 Alternative Seals for MTBE & Similar Applicati ons

Alternative 'Kalrez' Seals for MTBE & similar applica tions

‘O’ Ring (Replaces 37-0702-00) and Check Valve Tip (Replaces 36-1229-00)

12.4 Special Tools

Part/Sub- Assembly Commissioning 1 Year

Operation 2 Year Operation

Special Tool Kit (45-0127-00) comprising: 1

-

-

Description Part No. ‘C’ Spanners - Tool ‘A’ 36-2000-on Check Valve Nut / Lower Piston Rod Seal - Tool ‘E’

36-2004-00

Tommy Bar - Tool ‘F’ 36-2005-00 Seal Loading Mandrel - Tool ‘G’ 36-2006-00 Seal Sizing Tool - Tool ‘J’ 36-2017-00 Upper Sample Tube Seal Assembly Tool - Tool ‘L’

36-2015-00

Upper Capture Tube Seal Assembly Tool - Tool ‘M’

36-2016-00

¼” NPT Tommy Bar – Tool ‘P’ 36-2018-00

12.5 Ancillary Equipment Part/Sub- Assembly

Commissioning 1 Year Operation

2 Year Operation

Solenoid Coil (to suit application)

- 1 1


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def13 Product Specific Drawings

Master Drawing C29176

Master Drawing C16213

Seal Assembly Procedure E18098

14 2cc Cell Sampler The principle of operation of the 2cc version is identical to the standard 2” 210 MkIII Cell Sampler, but achieves the increased sample size through the use of larger diameter Capture and Sample Tubes and a modified pedestal on the Bottom Plug, causing a larger volume of product to be trapped.

Overhaul of the Sampler is very similar to the standard unit, the Bottom Plug overhaul being identical, with the exception of the larger diameter Seal and the Capture Tube Seal.

15 Disclaimer Whilst Jiskoot 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 Limited shall not be liable for incidental or consequential damages resulting from the furnishing, performance or use of this material.

Jiskoot pursue a policy of continuous improvement, and information given herein may be updated without notice.

Further, this information is proprietary to Jiskoot 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.

0 Fully Revised and updated as 2” MkIII Bolt on arrangement.

Reference 210 Cell R9 N. McGee P.Whittle 5/12/2007

Issue Revision History Issued Approved Date


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Tunbridge Wells, Kent, TN1 2DJ, UK Tel +44 (0)1892 518000, Fax +44 (0)1892 518100 e-mail: [email protected] www.jiskoot.com

Houston, TX77014, USA Tel +1 281 583 0583, Fax +1 281 583 0587 e-mail: [email protected] www.jiskoot.com

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