Sample Probe Module, SPM, User`s Manual

Sample
Probe
Module
User’s Manual
AA Swagelok
Swagelok®® Pre-Engineered
Pre-Engineered
Subsystem
Subsystem
• Pre-engineered subsystems
available in weeks, not months.
• Field-tested design ensures
optimum system performance.
Only available through authorized
Swagelok sales and service representatives.
2
Contents
Sample Probe Module System Manual . . . . . . . . . . . . . . . 3
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
SPV Heater Option . . . . . . . . . . . . . . . . . . . . . . . .
19
SPV Probe Packing Gland Lockout Bracket Option . . . . . . . 23
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 25
System Component User Instructions . . . . . . . . . . . . . . . 27
Swagelok Tube Fitting Instructions for 1 in. (25 mm)
and smaller fittings, MS-12-01 . . . . . . . . . . . . . . . . . 27
Packing Adjustment for 40G Series Ball Valves,
MS-INS-40G . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Only available through authorized
Swagelok sales and service representatives.
A Swagelok Pre-Engineered Subsystem
Sample Probe Module
3
Sample Probe
Module (SPM)
System Manual
Only available through authorized
Swagelok sales and service representatives.
A Swagelok Pre-Engineered Subsystem
Sample Probe Module
4
Introduction
The Swagelok® Sample Probe Module
(SPM) is a pre-engineered solution for use
in online process analyzers, that consists
of a welded sample probe (SPW) or
retractable probe (SPR) and a block-andbleed sample probe valve (SPV).
Configurations
Secondary
block valve
The SPV is available in four configurations.
See the Sample Probe Module Application
Guide, MS-02-425, for additional
information.
SPV61
Bleed valve
The SPV61 is a double block and bleed
valve containing a primary block valve, a
secondary block valve, and a bleed valve.
No interlocks are used on this configuration.
This configuration is intended for use with
welded probes.
Primary block
valve
SPV61
SPV62
The SPV62 is a double block and bleed
valve containing a primary block valve, a
secondary block valve, and a bleed valve
with the addition of mechanical valve
interlocks between the primary block valve
and the bleed valve.
Secondary
block valve
Bleed valve
This configuration is intended for use with
welded probes.
Valve
interlocks
Primary block
valve
Only available through authorized
Swagelok sales and service representatives.
SPV62
A Swagelok Pre-Engineered Subsystem
Sample Probe Module
5
Configurations
SPV63
The SPV63 is a single block and bleed
valve containing a primary block valve, a
bleed valve, and a probe lock spool with a
patent‑pending probe interlock.
The spool has thru-hole geometry
optimized for 1/4 in . and 3/8 in. retractable
tube probes.
Probe lock
spool
Bleed valve
Block valve
SPV63
SPV64
SPV64 a single block and bleed valve
containing a primary block valve, a bleed
valve, and a probe lock spool with a
patent‑pending probe interlock with the
addition mechanical valve interlocks
between the primary block valve and the
bleed valve.
Probe lock
spool
Valve
Interlocks
The SPV64 is optimized for 1/4 in. and
3/8 in. retractable tube probes.
Bleed valve
Block valve
SPV64
Only available through authorized
Swagelok sales and service representatives.
A Swagelok Pre-Engineered Subsystem
Sample Probe Module
6
Dimensions
Dimensions, in inches (millimeters), are for reference only and are subject to change.
SPW Welded Probes
Outlet and Inlet Flange
D dia,
E number
of holes
B
ASME B16.5 Flanges
Nominal
Flange
Size
3/4 in.
1 in.
1 1/2 in.
2 in.
ASME
Class
150
600
1500
150
600
150
600
1500
150
600
A
3.88
4.62
5.13
4.25
4.88
5.00
6.12
7.00
6.00
6.50
Dimensions, in.
B
C
2.75
0.57
3.25
1.13
3.50
1.51
3.12
0.63
3.50
1.20
3.88
0.76
4.50
1.39
4.88
1.76
4.75
0.83
5.00
1.51
D
0.62
0.75
0.88
0.62
0.75
0.62
0.88
1.13
0.75
0.75
Mounting
Holes
E
4
4
4
4
4
4
4
4
4
8
D
14
14
18
18
18
18
Mounting
Holes
E
4
4
4
4
4
4
D
19
19
19
23
19
19
Mounting
Holes
E
4
4
4
4
8
8
DIN 2526 Form C Flanges
Nominal
Flange
Size
25 mm
40 mm
50 mm
DIN
Class
PN16
PN40
PN16
PN40
PN16
PN40
A
115
115
150
150
165
165
Dimensions, mm
B
C
85
18
85
20
110
19
110
21
125
21
125
23
A
125
130
140
160
155
165
Dimensions, mm
B
C
90
15
95
23
105
18
120
26
120
18
130
28
A
C
8.0 to 36 in.
(203 to 914 mm)
Probe with Flush
Flange Outlet
JIS B2220 Flanges
Nominal
Flange
Size
25 mm
40 mm
50 mm
JIS
Class
16
40
16
40
16
40
Only available through authorized
Swagelok sales and service representatives.
A Swagelok Pre-Engineered Subsystem
Sample Probe Module
7
Dimensions
SPW Welded Probes
SPR Retractable Probes
1.00 (25.4)
cap hex
3.00
(76.2)
1.00 (25.4)
body hex
2.56
(65.0)
1/2 in.
male
NPT
8.0 to 36
(203 to 914)
8.0 to 36 in.
(203 to 914 mm)
A
Probe with
Stub Outlet
Stop collar
0.23
0.25 (5.8)
(6.4)
Tube Size
1/4 in.
3/8 in.
A, in. (mm)
0.38 (9.6)
0.50 (12.7)
Only available through authorized
Swagelok sales and service representatives.
A Swagelok Pre-Engineered Subsystem
Sample Probe Module
8
Dimensions
Dimensions, in inches (millimeters), are for reference only and are subject to change.
Double Block-and-Bleed SPV Sample Probe Valves (SPV61, SPV62)
0.87
(22.1)
SPV62 Shown
1.44
(36.6)
0.55 (14.0) orifice
3.21
(81.5)
1.88
(47.8)
Maximum thickness
of insulation
R
5.54
(141)
A
R
R
4.64
(118)
6.01
(153)
10.6
(269)
Inlet Size
1/2, 3/4 in.
1 in.
A, in. (mm)
9.48 (241)
9.74 (247)
Only available through authorized
Swagelok sales and service representatives.
A Swagelok Pre-Engineered Subsystem
Sample Probe Module
9
Dimensions
Single Block-and-Bleed SPV Sample Probe Valves (SPV63, SPV64)
0.87
(22.1)
SPV64 Shown
1.44
(36.6)
0.55 (14.0) orifice
3.21
(81.5)
1.88
(47.8)
Maximum thickness
of insulation
4.50
(114)
A
R
R
10.4
(264)
Inlet Size
1/2, 3/4 in.
1 in.
4.64
(118)
6.01
(153)
A, in. (mm)
8.44 (214)
8.69 (221)
Weight, All Configurations
22 lb (10 kg)
Only available through authorized
Swagelok sales and service representatives.
A Swagelok Pre-Engineered Subsystem
Sample Probe Module
10
Installation
SPV61 and SPV62 Sample
Probe Valve with
SPW Welded Probe Installation
 Warning
Depressurize
the system before
installing the SPV and SPW.
1. Relieve pressure from the system.
2. Verify the probe is the correct length
for your application. Swagelok
recommends the end of the probe reach
the middle third of the process pipe.
3. Connect the SPW probe to a flanged
process nozzle. Use the visual indicator
on the flange to orient the angled cut on
the end of the probe downstream.
4. Actuate all valves on the SPV to the
6. Connect the outlet of the SPV to the
system outlet line.
7. Connect the bleed valve outlet of the
SPV to the system vent line.
8. If necessary, add support by mounting
to any of the four heater mounting holes
(longer M8 bolts may be needed) or the
two thru holes on the lower left corner
of the body. Additional support is more
likely to be needed when any of the
following conditions exist.
a.The SPV is mounted horizontally.
b.The SPV does not have a rigid outlet
or bleed valve outlet connection
(Configurations 61 and 63).
c.The SPV does not have a heater
connected with rigid conduit.
d.The SPV inlet connection is 1/2 in.
NPT.
e.The valve will experience significant
vibration.
9. Supply pressure and check for inlet
connection leaks using Snoop® liquid
leak detector.
10.Open the primary and secondary block
valves and check for connection leaks
using Snoop liquid leak detector.
Probe Visual Indicator
closed position.
5. Connect the SPV inlet to the SPW.
a. SPW with pipe stub outlet - connect
the SPV inlet directly to the NPT
pipe stub on the SPW. (Use adapter
fittings as necessary for different size
connections.)
b. SPW with flange outlet - use a flange
adapter and appropriate pipe fittings
(not supplied) to connect the SPV
inlet to the SPW outlet flange.
Only available through authorized
Swagelok sales and service representatives.
A Swagelok Pre-Engineered Subsystem
Sample Probe Module
11
Installation
Outlet
Secondary
block valve
Bleed valve
outlet
Bleed valve
Primary block
valve
Inlet
SPW with stub option
Flanged process
interface nozzle
SPV62 with SPW Welded Probe
Only available through authorized
Swagelok sales and service representatives.
A Swagelok Pre-Engineered Subsystem
Sample Probe Module
12
Installation
SPV63 and SPV64 Sample
Probe Valve with SPR
Retractable Probe Installation
 Warning
You
must depressurize the
system before installing the SPV
10.If necessary, add support by mounting
to any of the four heater mounting holes
(longer M8 bolts may be needed) or the
two thru holes on the lower left corner
of the body. Additional support is more
likely to be needed when any of the
following conditions exist.
a.The SPV is mounted horizontally.
b.The SPV does not have a rigid outlet
or bleed valve outlet connection.
2. Actuate both valves and the probe lock
spool on the SPV to the closed position.
c.The SPV does not have a heater
connected with rigid conduit.
3. Connect the valve inlet to the sample
supply line.
d.The SPV inlet connection is 1/2 in.
NPT.
4. Connect the bleed valve outlet to the
system vent line.
e.The valve will experience significant
vibration.
5. Verify the probe is the correct length
for your application. Swagelok
recommends the end of the probe reach
the middle third of the process pipe.
11.Check for inlet connection leaks using
Snoop liquid leak detector.
and SPR.
1. Relieve pressure from the system.
6. For SPRs without the optional probe
isolation valve, install an appropriate
isolation valve to the outlet of the tube
probe. Orient the valve with the handle
upstream.
7. Actuate the isolation valve to the closed
position.
8. Connect the retractable probe packing
gland body to the 1/2 in. NPT SPV
outlet.
12.Open the primary block valve. Verify
the bleed valve is in the closed position.
Check for connection leaks using Snoop
liquid leak detector.
13.Open the probe lock spool.
14.Slightly loosen the probe packing gland
cap 1/64 turn at a time until the probe
can be inserted through the SPV.
15.Install the probe to the desired insertion
depth. Use the visual indicator on the
tube probe for orientation.
9. Tighten the probe packing gland cap
according to the table.
Seal Material
Fluorocarbon
FKM
Grafoil®
PTFE
Torque, ft·lb (N·m)
55 to 60
(74.5 to 81.3)
55 to 60
(74.5 to 81.3)
90 to 100
(122 to 135)
16.Set the probe in the desired orientation,
typically with the cut angle facing
downstream. Tighten the packing gland
cap according to the table.
17.Supply pressure and check for
connection leaks using Snoop liquid
leak detector.
Only available through authorized
Swagelok sales and service representatives.
18.Connect the outlet port of the probe
isolation valve to the system outlet line.
A Swagelok Pre-Engineered Subsystem
Sample Probe Module
13
Installation
Probe isolation
valve
Tube
probe
Outlet
Cap
Body
Probe packing
gland
Primary block valve
Bleed valve
Probe lock spool
(red handle)
Bleed valve
outlet
Inlet
SPV64 with SPR Retractable Probe
Only available through authorized
Swagelok sales and service representatives.
A Swagelok Pre-Engineered Subsystem
Sample Probe Module
14
Installation
SPV Sample Probe Valve
Installation
Assemble Swagelok tube fittings according
to Swagelok Tube Fitting Installations for 1
in. (25 mm) and Smaller Fittings, page 27.
 Warning
You
must depressurize the
system before installing the SPV.
9. Open the primary block valve and check
for connection leaks using Snoop liquid
leak detector.
10.Open the secondary block valve and
check for connection leaks using Snoop
liquid leak detector (Configurations 61
and 62).
1. Relieve pressure from the system.
2. Actuate all valves to the closed position.
3. Connect the valve inlet to the sample
supply line.
4. Configurations 61 and 62 only: Connect
the outlet to the outlet line.
5. Configurations 63 and 64 only: It is
recommended to plug the outlet port
until a retractable probe is installed.
6. Connect the bleed valve outlet to the
system vent line.
7. If necessary, add support by mounting
to any of the four heater mounting holes
(longer M8 bolts may be needed) or the
two thru holes on the lower left corner
of the body. Additional support is more
likely to be needed when any of the
following conditions exist.
a.The SPV is mounted horizontally.
b.The SPV does not have a rigid outlet
or bleed valve outlet connection
(Configurations 61 and 63).
c.The SPV does not have a heater
connected with rigid conduit.
d.The SPV inlet connection is 1/2 in.
NPT.
e.The SPV will experience significant
vibration.
8. Supply pressure to the valve and check
for connection leaks using Snoop liquid
leak detector.
Note: T
he probe interlock valve on
Configurations 63 and 64 does not
have a seat shut-off seal and will
always allow flow to pass through in
both the open and closed positions.
Only available through authorized
Swagelok sales and service representatives.
A Swagelok Pre-Engineered Subsystem
Sample Probe Module
15
Installation
Outlet
Secondary
block valve
Bleed valve
outlet
Mounting
holes
Inlet
Primary block
valve
SPV61
Only available through authorized
Swagelok sales and service representatives.
A Swagelok Pre-Engineered Subsystem
Sample Probe Module
16
Operation
General notes:
SPV64
1. The valve is closed when the handle
crosses the flow path.
The valve contains a primary block valve
(PBV), a bleed valve (BLV) and a probe lock
spool (PLS), with interlocks between the
PBV and PLS as well as valve interlocks
between the PBV and BLV.
2. The valve is open when the handle is
inline with the flow path.
SPV61
All valve handles are free to open and close.
SPV62
The secondary block valve (SBV) is free to
open and close.
The primary block valve (PBV) and the
bleed valve (BLV) are interlocked which
prevents specific valve handles from being
actuated under certain conditions. When
either the PBV or BLV is open the other is
locked closed.
The PBV and the BLV can be closed at the
same time.
The primary block valve (PBV) and the
bleed valve (BLV) are interlocked which
prevents specific valve handles from being
actuated under certain conditions. When
either the PBV or BLV is open the other is
locked closed.
The PBV and the BLV can be closed at the
same time.
The primary block valve (PBV) can only be
closed when the probe lock spool (PLS)
is in the closed position. This prevents a
probe from being inserted through the valve
and damaging the PBV sealing ball. When
the PBV is in the closed position, interlocks
prevent the PLS from being opened. When
the PBV is in the open position the PLS
can be opened to allow the insertion of a
retractable probe.
SPV63
The bleed valve (BLV) is free to open and
close.
The primary block valve (PBV) can only be
closed when the probe lock spool (PLS)
is in the closed position. This prevents a
probe from being inserted through the valve
and damaging the PBV sealing ball. When
the PBV is in the closed position, interlocks
prevent the PLS from being opened. When
the PBV is in the open position the PLS
can be opened to allow the insertion of a
retractable probe.
Only available through authorized
Swagelok sales and service representatives.
A Swagelok Pre-Engineered Subsystem
Sample Probe Module
17
Maintenance
Follow these steps before performing any
downstream system maintenance.
SPV Sample Probe Valve with
SPW Welded Probe
1. Close the primary block valve.
2. Open the bleed valve.
Note: T
his will depressurize the
downstream analytical system to
the next check valve.
Secondary
block valve
(shown open)
3. Close the secondary block valve.
 Warning
The
probe is still under
pressure from the process line.
Bleed valve
(shown
closed)
Primary block valve
(shown open)
Depressurize the process line and
system before performing any
maintenance on the valve or the
probe.
SPV62 with SPW Welded Probe
Only available through authorized
Swagelok sales and service representatives.
A Swagelok Pre-Engineered Subsystem
Sample Probe Module
18
Maintenance
SPV Sample Probe Valve
with SPR Retractable Probe Removing the Probe
 WARNING
Excessive
loosening of the probe
packing gland will result in
sudden extraction of the probe
from the system or leakage.
1. Slightly loosen the probe packing gland
cap 1/64 turn at a time until the probe
can be retracted by pulling it through
the SPV.
3. Close the probe lock spool (PLS).
4. Close the primary block valve (PBV).
5. Open the bleed valve (BLV).
Note: T
his will depressurize the
downstream analytical system to
the next check valve.
6. Remove the probe from the SPV by
removing the probe packing gland body.
2. Pull the probe through the SPV until the
stop collar contacts the probe packing
gland body.
Probe isolation
valve
Cap
Body
Probe packing
gland
Primary block
valve
Probe lock spool
(red handle)
Only available through authorized
Swagelok sales and service representatives.
SPV64 with SPR Retractable Probe
A Swagelok Pre-Engineered Subsystem
Sample Probe Module
19
SPV Heater Option
General Safety
Configurations
The optional heater comes in two voltages
(120 VAC or 240 VAC) and the heater block
comes in two materials (316 stainless steel
or black anodized aluminum).
WARNING: HOT SURFACE
External surfaces of this product
may reach temperatures of over
250°F (120°C) during normal
operation.
All heaters contain a non-resettable thermal
fuse that interrupts power to the heater
before the heater reaches 392°F (200°C).
All heaters include a solid state PID
temperature controller that can be adjusted
from 50 to 300°F (10 to 148°C)
3/4 in. Female NPT
Heater Assembly
Only available through authorized
Swagelok sales and service representatives.
A Swagelok Pre-Engineered Subsystem
Sample Probe Module
20
SPV Heater Option
Heater Installation
SPV heater kits mount to the SPV to heat
and maintain a specific temperature. The
heater can be set to maintain the heater
block temperature from 50°F to 300°F (10°C
to 148°C). The environmental temperature
rating of the heater is -4°F to 122°F (-20°C
to 50°C).
Kit Contents
• Heater assembly
• (4) M8 × 55 hex head screws
SPV62 with Heater Installed
• (4) M8 lock washers
Tools needed
• 13 mm wrench or socket
• T
orque wrench capable of 120 in.·lbs
(13.5 N·m)
Only available through authorized
Swagelok sales and service representatives.
A Swagelok Pre-Engineered Subsystem
Sample Probe Module
21
SPV Heater Option
Heater Installation
 WARNING
Disconnect
power to the heater
before opening electrical box
1. Remove the four M8 hex screws
covering the heater mounting holes on
the valve body mounting surface.
2. Clean the valve body mounting surface.
lid. Failure to do so may result
in electric shock and may also
present an explosion hazard.
3. Position the heater on the body and
assemble using the supplied M8 × 55
mounting bolts and washers. Tighten
the bolts to 120 in.·lbs (13.5 N·m).
 WARNING
The
supply must not exceed
110 % of the rated voltage.
4. Remove the junction box cover and
make the wire and conduit connections.
The installation must meet local codes.
The junction box has a 3/4 in. female
NPT thread connection. The electrical
source and wires must meet the
minimum wire gauge size and maximum
current draw for a 110/240 VAC 500W
50/60 Hz heater draw.
 CAUTION
Use
appropriate wire and
connections to withstand the
temperature range of the heater.
Note: T
here is a limited thread engagement
of the terminal block mounting
screws in the aluminum mounting
plate. The use of anaerobic thread
locking adhesive and a low tightening
torque are recommended.
a.Make a ground connection, an
internal ground and an external
ground screw are provided.
b.Connect the AC supply to the
standoff pillars labeled 2 and 4.
5. Replace the junction box cover.
M8 × 55
6. The handles on the SPV valve have large
mounting bolt
stand-off distances to accommodate up
to 1 in. (25 mm) thick insulation around
the heater and valve assembly.
External ground
screw
Internal
ground
lead
Lock
washer
Valve body
mounting
surface
SPV62 with Heater
AC supply connected
to top of standoff pillars
2 and 4.
3/4 in. NPT gland
connection
Thermistor wire
(blue)
Heater wire
(tan)
Only available through authorized
Swagelok sales and service representatives.
Heater Wire Connections
A Swagelok Pre-Engineered Subsystem
Sample Probe Module
22
SPV Heater Option
Heater Operation
 WARNING
Disconnect
power to the heater
before opening electrical box
lid and setting the temperature.
Failure to do so may result in
electric shock and may also
present an explosion hazard.
1. Disconnect power to the heater.
Allow at least 60 minutes for the
temperature to reach the revised set
point. The temperature of the valve body
can be monitored using the optional dial
thermometer or by other user supplied
means. Depending on environmental
conditions and whether the valve is
insulated, more time may be required for the
heater to reach the set temperature.
2. Remove the electrical box lid.
3.Turn the adjuster screw located on the
control unit to the required temperature
position/setting as indicated on the
label.
Note: T
urn the screw fully
counterclockwise for position 1
and fully clockwise for postion 3.
4. Replace the electrical box lid.
5. Reconnect unit to power.
Note: It is recommended to insulate
the valve and heater assembly
by wrapping the assembly
with insulation when there is
a temperature difference of
more than 50°F (10°C) between
the set temperature and the
environmental temperature.
Adjuster screw
External ground
screw
Internal
ground
lead
AC supply connected
to top of standoff pillars
2 and 4.
3/4 in. NPT Gland
connection
Thermistor wire
(blue)
Heater wire
(tan)
Heater Wire Connections
Only available through authorized
Swagelok sales and service representatives.
A Swagelok Pre-Engineered Subsystem
Sample Probe Module
23
SPV Probe Packing Gland
Lockout Bracket Option
Configuration
This option prevents unintentional loosening
of the probe packing gland cap or removal
of the probe fitting with a retractable probe.
Installation
The probe lock kit is designed to be
installed on SPV Configurations 63 or 64.
Kit Contents:
• Base plate
• Cover plate
• (1) M8 countersink screw
• (1) M8 shoulder screw
SPV64 with Probe Gland Lockout Bracket
Tools needed:
• 5 mm hex key
• (1) Flat washer
• (1) Wave spring washer
• Thread lock adhesive
• 13 mm wrench or socket
orque wrench capable of 120 in.·lbs
• T
(13.5 N·m)
Only available through authorized
Swagelok sales and service representatives.
A Swagelok Pre-Engineered Subsystem
Sample Probe Module
24
SPV Probe Packing Gland
Lockout Bracket Option
Installation
1. Remove the two existing M8 hex
screws.
2. Align both holes in the base plate to the
threaded holes on the SPV body.
3. Apply a couple drops of thread
lock adhesive to the thread of the
M8 countersink screw. Use the M8
countersink screw to hold the base
plate in position but do not tighten at
this time.
4. Place the cover plate on top of the base
plate and align the left hole in the cover
plate with the left hole on the base plate
with the left threaded hole on the SPV
body.
5. Place the wave spring washer then the
flat washer over the shoulder of the M8
shoulder screw.
6. Apply a couple drops of thread lock
adhesive to the thread of the M8
shoulder screw. Install the screw
through the cover plate, base plate and
into the valve body. Turn the shoulder
screw clockwise until the shoulder fits
through the washer and cover plate and
stops against the base plate but do not
tighten at this time.
Note: T
he cover plate will lock in
position if the washer is not
aligned properly.
7. Rotate the cover plate counterclockwise
to expose the M8 countersink screw.
Tighten the M8 countersink screw to
120 in.·lbs (13.5 N·m).
8. Tighten the M8 shoulder screw to
120 in.·lbs (13.5 N·m). The cover plate
can should swing/pivot from the fully
open position to the fully locked position
and the lock ring on the cover plate
should pass through the slot on the
base plate.
Base plate
Cover plate
Flat washer
Wave spring
washer
M8 shoulder
screw
M8
countersink
screw
Only available through authorized
Swagelok sales and service representatives.
Exploded View of Probe Packing Gland Lockout Bracket Option
A Swagelok Pre-Engineered Subsystem
Sample Probe Module
25
Troubleshooting
Symptom
Cause
Remedy
SPM Troubleshooting
SPV62 and SPV64
Primary block valve will not open.
Primary block valve is
locked closed by the
bleed valve.
Close the bleed valve. The
bleed valve must be closed
before the primary block valve
can be opened.
Bleed valve will not open.
Bleed valve is locked
closed by the primary
block valve.
Close the primary block valve.
The primary block valve must
be closed before the bleed
valve can be opened.
SPV63 and SPV64
Primary block valve will not close.
Primary block valve
is locked open by the
probe lock valve.
Retract the probe (if installed)
then close the probe lock
valve. The probe lock valve
must be closed before the
primary block valve can be
closed.
Probe lock valve will not fully open.
Probe lock valve is
locked closed by the
primary block valve.
Open the primary block valve.
The primary block valve must
be opened before the probe
lock valve can be opened.
A probe is installed
through the valve
and preventing the
probe lock valve from
closing.
Fully retract the probe until
the stop collar contacts the
packing gland body. Close the
probe lock valve.
The probe is impeding
closing of the probe
lock valve.
Verify that the probe is fully
retracted. If it is, then the
distance from the back stop
of the stop collar to the end of
the probe may be too long.
Probe lock valve will not fully
close.
SPR and SPW assemblies
Low flow or no flow downstream of
the tube probe.
Sample response time is too slow.
There is leakage around the
packing gland.
The probe is partially
or fully clogged.
Clean out the probe. Consider
a probe with a larger inside
diameter.
The angle cut on the
probe end is incorrect.
Change the probe orientation
so the open end faces
downstream.
Excessive internal
volume.
Reduce the internal volume.
Consider a probe with a
smaller inside diameter.
Excessive gas
pressure.
Reduce the gas pressure
downstream. Consider
installing a Swagelok Field
Station Module immediately
downstream.
The packing gland
cap needs to be
adjusted.
Tighten the packing gland cap
according to the torque table
on page 12.
The packing gland
sealant needs to be
replaced.
Replace the packing gland
sealant.
Only available through authorized
Swagelok sales and service representatives.
A Swagelok Pre-Engineered Subsystem
Sample Probe Module
26
Troubleshooting
Symptom
Cause
Remedy
Heater Troubleshooting
Heater block does not heat up and
reach the set temperature.
Heater not getting
appropriate power.
Check voltage at the supply
terminals 2 and 4.
Should be around 120V or
around 240V, depending on
heater.
Controller set
temperature is below
ambient temperature.
Adjust controller set
temperature to above ambient
temperature.
Thermal fuse tripped.
Check continuity across
terminals 1 and 4. If no
continuity then replace heater
block.
Faulty reading from
thermistor.
Check resistance across
terminals 2 and 3. If the
resistance is zero or infinity
then thermistor is faulty.
Return unit to factory. A
properly functioning thermistor
will show a steady increase
in resistance while heating up
and a steady decrease while
cooling down.
Excessive heat
losses preventing
heater from reaching
set temperature or
causing more time for
heater to reach the set
temperature.
Insulate valve body and
heater or decrease the set
temperature.
Controller set
temperature is below
ambient temperature.
Ambient temperature must
be below controller set
temperature and the process
temperature for heater to cool
down. Adjust controller set
temperature to above ambient
temperature or reduce ambient
temperature or reduce process
temperature.
Faulty reading from
thermistor.
Check resistance across
terminals 2 and 3. If the
resistance is zero or infinity
then thermistor is faulty
and return unit to factory. A
properly functioning thermistor
will show a steady increase
in resistance while heating up
and a steady decrease while
cooling down.
Cooling down takes
too long.
Larger temperature differences
between set point and ambient
temperatures may result in
increased cooling times. Allow
more time for heater to cool
down.
Ambient or process
temperature is
fluctuating.
Reduce ambient and/
or process temperature
fluctuations.
Controller PID settings
too aggressive for the
application.
Reset controller and if
symptom/problem persists
return unit to factory.
Heater block does not cool down
and reach the set temperature.
Only available through authorized
Swagelok sales and service representatives.
Temperature fluctuates and does
not stabilize.
A Swagelok Pre-Engineered Subsystem
Sample Probe Module
27
Swagelok Tube Fitting Instructions
for 1 in. (25 mm) and smaller
fittings
Fig. 1
Fig. 2
Fig. 3
Installation
These instructions apply to both traditional
fittings and to fittings with the advanced backferrule geometry.
1.Fully insert the tube into the fitting and
against the shoulder; rotate the nut fingertight. Fig. 1.
High-Pressure Applications and High
Safety-Factor Systems: Further tighten the
nut until the tube will not turn by hand or
move axially in the fitting.
2.Mark the nut at the 6 o’clock position. Fig. 2.
3.While holding the fitting body steady, tighten
the nut one and one-quarter turns to the
9 o’clock position. Fig. 3.
Note: For 1/16, 1/8, and 3/16 in.; 2, 3,
and 4 mm tube fittings, tighten the nut
three‑quarters turn to the 3 o’clock position.
Gaugeability
On initial installation, the Swagelok gap
inspection gauge assures the installer or
inspector that a fitting has been sufficiently
tightened.
Position the Swagelok gap inspection gauge
next to the gap between the nut and body.
Fig. 4.
• If the gauge will not enter the gap, the fitting
is sufficiently tightened.
• If the gauge will enter the gap, additional
tightening is required.
Reassembly Instructions — You may
disassemble and reassemble Swagelok tube
fittings many times.
Fig. 4
Warning
Always depressurize the system before
disassembling a Swagelok tube fitting.
1.Prior to disassembly, mark the tube at the
back of the nut; mark a line along the nut
and fitting body flats. Fig. 5.
Use these marks to ensure you return the nut to
the previously pulled-up position.
2.Insert the tube with preswaged ferrules into
the fitting body until the front ferrule seats
against the fitting body. Fig. 6.
3.While holding the fitting body steady, rotate
the nut with a wrench to the previously
pulled-up position as indicated by the marks
on the tube and the flats; at this point you
will feel a significant increase in resistance.
Fig. 7.
4.Tighten the nut slightly.
Fig. 5
Fig. 6
Caution
Do not use the gap inspection gauge
with reassembled fittings.
Fig. 7
Caution
Do not mix or interchange parts with
those of other manufacturers.
Only available through authorized
Swagelok sales and service representatives.
For additional information, see the Gaugeable
Tube Fittings and Adapter Fittings catalog,
MS-01-140.
A Swagelok Pre-Engineered Subsystem
Sample Probe Module
28
40G Series Valve Packing Adjustment
IMPORTANT
This valve is factory tested with nitrogen at
1000 psig (69 bar), or the rated pressure if
lower than 1000 psig (69 bar).
Periodic maintenance: Packing
adjustments may be required during
the service life of the valve to prevent
leakage.
Adjusting the Packing
1.Adjust the packing by turning the packing
bolt clockwise in 1/16-turn increments
until leak-tight performance is achieved.
2.Test valve for proper function and
operation.
Before removing any installed valve
from the system, you must
• depressurize the system
• cycle the valve
• purge the valve
Only available through authorized
Swagelok sales and service representatives.
A Swagelok Pre-Engineered Subsystem
Sample Probe Module
29
Only available through authorized
Swagelok sales and service representatives.
A Swagelok Pre-Engineered Subsystem
Sample Probe Module
Warranty Information
Swagelok products are backed by The Swagelok Limited
Lifetime Warranty. For a copy, visit swagelok.com or
contact your authorized Swagelok representative.
Only available through authorized
Swagelok sales and service representatives.
Swagelok, Snoop — TM Swagelok Company
Conax — TM Conax Technologies, Grafoil — TM GrafTech Internation Holdings, Inc.
© 2011 Swagelok Company
April 2011, R0
MS-13-220