Installation, Operation, and

Maintenance Manual

Welker® Probe Instrument Regulator

Model
IRD-4SSF

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.

13839 West Bellfort

Sugar Land, Texas 77498-1671
U.S.A.
Tel.: (800) 776-7267
Tel.: (281) 491-2331
Fax: (281) 491-8344
www.welkereng.com

© Copyright 2009, Welker Inc.

 This page intentionally left blank

© Copyright 2009, Welker Inc.

TABLE OF CONTENTS

1. GENERAL 4

1.1 INTRODUCTION 4
1.2 DESCRIPTION OF PRODUCT 4
1.3 SPECIFICATIONS 5

2. INSTALLATION INSTRUCTIONS 7

2.1 GENERAL 7
2.2 IMPORTANT INFORMATION 7
2.3 INSTALLATION INSTRUCTIONS 8

3. MAINTENANCE 10

3.1 GENERAL 10
3.2 INSTRUMENT REGULATOR MAINTENANCE 11
3.3 RELIEF VALVE (RV-1) MAINTENANCE 12
3.4 PROBE MAINTENANCE 13

Welker®, Welker Jet®, and WelkerScope® are Registered Trademarks owned by Welker, Inc .

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SPECIFICATIONS

1. GENERAL
1.1 Introduction
We appreciate your business and your choice of Welker products. The installation,
operation, and maintenance 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 performance prior to use. If you have any questions,
please call 1-800-776-7267 in the USA or 1-281-491-2331.
The following procedures have been written for use with standard Welker parts and
equipment. Assemblies that have been modified may have additional requirements and
specifications that are not listed in this manual.

Notes, Warnings, and Cautions

Notes emphasize information or set it off from the surrounding text.

Caution messages appear before procedures that, if not observed, could result
in damage to equipment.

Warnings alert users to a specific procedure or practice that, if

not followed correctly, could cause personal injury.

1.2 Description of Product

The Welker Probe Instrument Regulator is designed to
serve as a probe and a regulator combination while
minimizing the Joule-Thomson effect by design. Supply
enters through the tip of the probe and is regulated to a
reduced pressure and immediately passes through thermal
exchange fins before exiting the flowing stream in the
pipeline. The body houses the output adjustment and
spring along with output port, gauge port, and safety relief
port.

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SPECIFICATIONS

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. However, please note that the specifications may vary
depending on the customization of your product.

Table 1

Specifications
Natural gas or other gases or liquids compatible
Products
with the materials of construction
® ®
316 Stainless Steel, Viton , PTFE, Buna-N , and
Materials of Construction ®
Kel-f (others available)
1
/4" NPT
Sample Outlet Connection
(others available)
1
/4" NPT
Sample Inlet Connection
(others available)
1 3
Pipeline Connection /2", /4", and 1" NPT

Maximum Allowable Inlet IRD-4:

Pressure* 2,160 psi @ -20° F to 100 ° F
(248 bar @ -29° C to 37° C)

IRD-4:
Output Range* 0-100 psi @ -20° F to 100 ° F
(0-6 bar @ -29° C to 37° C)

Temperature Range* -40° F to 275° F

*Maximum allowable pressures, output ranges, and temperature ranges may differ depending on specifications of the pipeline
connection device.

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INSTALLATION & OPERATIONS

2. INSTALLATION INSTRUCTIONS
2.1 General
After unpacking the unit, check it for compliance and for any damages which may have
occurred during shipment.

Claims for damages caused during shipping must be initiated by the receiver and directed to the
shipping carrier. Welker is not responsible for any damages caused from mishandling by the
shipping company.

When sealing fittings with PTFE tape, refer to the proper sealing instructions for the tape used.
Recommended Tools
It would be advisable to have the following tools available for
installation of the unit; however, tools used will vary depending
on model.
• 10" adjustable wrench
• Tubing
• Tubing cutters

2.2 Important Information

1. Always depressurize the pipeline when

installing or removing the probe.
2. Avoid rough handling of the probe and
unnecessary bending of the probe shaft. The
shaft has a polished surface that travels
through a seal.
3. The entire instrument should be treated with
care.

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INSTALLATION & OPERATIONS

2.3 Installation Instructions

The preferred location for installation into the pipeline is in a straight section of inlet piping before the
flowing stream is subjected to turns and impingements that can produce aerosols. Aerosols can
contaminate the sample being taken.

1. Close the appropriate pipeline valves in

order to depressurize the pipeline.
2. Use a safe auxiliary gas supply to set the
relief valve to the proper pressure.
3. If necessary, follow steps in number 4 of
this section, using a safe auxiliary gas
supply to set the relief valve to the proper
pressure. If relief is preset, skip to number 5
of this section.
4. Set the Relief Valve (RV-1D) (Figure 2):
Figure 2
Relief Valve
If requested, Welker can preset Welker
relief valves prior to shipment.

• Use a hex wrench to adjust the spring

tension in the relief valve for positive
shut-off.
• Adjust the relief to the desired set point.

5. The relief valve is now in operation. Connect the set relief valve to the relief valve
port in the regulator.
6. Tube the relief valve to vent to a safely designated ventilation port.
7. Close the appropriate pipeline valves in order to depressurize the pipeline.
8. Connect the probe regulator to the appropriate pipeline connection. Bolt the
flange to the pipeline.
9. Back off the adjusting screw to the regulator to prevent any pressure from
escaping.
10. If necessary, connect a gauge to the gauge port in the regulator.
11. Use tubing to connect from the outlet port on the regulator to the inlet of the
instrument.
12. Open the appropriate pipeline valves to pressurize the pipeline.

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INSTALLATION & OPERATIONS

13. The regulator is now ready to be set to the

desired output pressure.
14. Set the Instrument Regulator to desired
pressure setting:
• Make sure the pipeline is providing pressure to the regulator.
• Turn the inlet supply to pressurize the regulator inlet.
• Loosen or tighten the adjusting screw until the gauge reads the desired pressure
for outlet (See Figure 3).
• Tighten the jam nut (Part 2) on the adjusting screw (Part 1) to secure it into
place.
• The regulator is now in operation.

Figure 3
Setting the Instrument
Regulator

15. Cheak for leaks.

16. The probe is now in service.

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MAINTENANCE

3. MAINTENANCE
3.1 General

Prior to maintenance or disassembly of the unit, it is advisable to have a repair kit handy
for the system in case of unexpected wear or faulty seals. All maintenance and cleaning
of the unit should be done on a smooth, clean surface.

We recommend that the unit have annual maintenance under normal operating conditions. In the
case of severe service, dirty conditions, excessive cycling usage, or other unique applications that
may subject the equipment to unpredictable circumstances, a more frequent maintenance schedule
may be appropriate.

New seals supplied in spare parts kits are not lubricated. They should be lightly coated with lubrication
grease (Dow Corning 111 [DC 111] or equivalent lubricant) before they are installed into the equipment.
This helps with the installation of the seals while reducing the risk of damage when positioning them on
the parts.

Maintenance on the instrument regulator should not be performed until the regulator has been
isolated from all pressure.

Recommended Tools
It would be advisable to have the following tools
available for maintenance of the unit. However,
tools used will vary depending on model.
• Small hex key set
• 10" adjustable wrench
• Cleaning solvent

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MAINTENANCE

3.2 Instrument Regulator Maintenance

(See Figure 3)

1. Close the appropriate pipeline valves

to depressurize the pipeline.
Disconnect the instrumentation from
the regulator’s outlet port. Remove
the probe from the pipeline.
2. Loosen the adjusting nut (Part 2) on
the adjusting screw (Part 1).
3. Loosen the adjusting screw to relieve
tension on the spring (Part 6).
4. Disassemble Diaphragm Assembly:
a) Unscrew the spring housing (Part 4)
and remove.
b) Remove the top spring guide (Part 5) Figure 3
and the spring (Part 6). Instrument Regulator
c) Remove the bottom spring guide (Part 7).
d) Remove the diaphragm assembly (Part 8). Inspect for wear, and replace if
necessary.
e) Set the diaphragm back into place.
f) Set the bottom spring guide back into place on top of the diaphragm.
5. Set the spring (Part 6) back into place.
6. Set the top spring guide (Part 5) back into place on top of the spring.
7. Reattach the spring housing (Part 4) securely. Hand-tighten the housing.
8. Proceed to Section 3.3 for relief valve maintenance.

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3.3 Relief Valve (RV-1) Maintenance

(See Figure 4)

Figure 4
Relief Valve (RV-1D)

1. Isolate and depressurize the relief valve from the supply source.
2. Remove the relief valve from the supply.
3. Remove the spring adjuster, spring and ball.
4. If the spring is in good condition, it can be reused.
5. Check the ball for nicks and scratches and replace if necessary.
6. Unscrew the base from the spring housing and replace the seal (See Figure 5).
7. Screw the base and spring housing back together.
8. Drop the ball and spring into the spring housing.

The ball must rest on the seal. If the ball rests on the
metal trim, then the relief will not seat.
9. Replace the spring adjuster.
10. The relief valve is ready to reinstall and reset.
11. Proceed to Section 3.4 for probe maintenance
instructions.

Figure 5
Seal

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MAINTENANCE

3.4 Probe Maintenance Instructions

(See Figure 5)
1. Use a pair of channel lock pliers as a backup to hold the thermal fins (Part 16)
while using another pair to remove the seat retainer (Part 20).

Figure 5
Thermal Fins & Retainer

2. Remove the poppet spring (Part 17) and the poppet (Part 14).
3. Use a pointed instrument to carefully pick the seat (Part 15) out of the body of the
thermal fin.
4. Examine the poppet and the seat for scratches. If scratches are present, the part will
need to be replaced.

Debris or scratches on either the poppet or the seat will prevent positive shut-off of the regulator.
5. Guide the poppet into the seat.
6. Replace the spring and seat retainer.
7. Tighten the seat retainer firmly.
8. Replace the O-ring (Part 16) on the shaft.
9. If there is a shaft extension, remove the extension from the thermal fins.
10. Reattach the thermal fins to the shaft. Tighten firmly.

When reattaching the base to the body, make sure that the contact rod and push rod are carefully
installed and lined up correctly. The push rod should fit easily over the poppet and should not
stack on top of it. If the rod is stacked on top of the poppet, the device will not be able to be
reassembled properly.

11. Follow instructions in Section 2.3 to reinstall the probe assembly.

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13839 West Bellfort, Sugar Land, Texas 77498-1671
Phone: (281) 491-2331
Fax: (281) 491-8344
Toll Free: (800) 776-7267
Web Page: www.welkereng.com