Manual Hydrill K20-5000

Manual No.3111330-07011OM-Rev A Operator’s Manual R OPERATOR’S MANUAL PAGE 1 K80-3705 Pulsation Dampener HYDRIL® K20-5000 PULSATION DAMPENER R R Pressure Control Equipment August 2000 • All Rights Reserved . All information contained in this manual is the exclusive property of Hydril Company. R ©2000 Hydril Company • HYDRIL COMPANY/P. 3111330-07011 Please contact Hydril Pressure Control Equipment for any assistance or questions concerning the information in this manual.A. TEXAS 77205 TELEPHONE: (281) 449-2000/TELEX 168905 HYDRIL CSD HOU/ FAX: (281) 985-2828 Printed In The U. BOX 60458/HOUSTON.O.Operator’s Manual R PAGE 1 K20-5000 Pulsation Dampener R K20-5000 Pulsation Dampener Complete Assembly Hydril Part No..S. including any warranty of mechanical fitness for any particular purpose that the work performed pursuant to this manual will be free from defects in workmanship or material. inspection. Hydril retains for itself all proprietary rights in and to all designs. and for workmanship and safety.PAGE 2 Operator’s Manual R K20-5000 Pulsation Dampener PREFACE Hydril makes no warranties of any kind. The customer is also solely responsible for providing competent and qualified persons. If at any time the customer is unable to understand the recommendations made in this manual or is unable to follow those recommendations. engineering details. expressed or implied. re-assembly and testing of the pulsation dampener body. they should consult the nearest Hydril location. This manual is intended for the sole use of Hydril customers and they shall strictly control copying of same. as this manual and all copies thereof may be recalled by Hydril at any time. data and procedures set forth herein. This manual makes recommendations only. . equipment and facilities to perform such operations. The customer is at all times responsible for actual disassembly. . . . . .. . . . . . . .. . . . . . . . . . . . . . . . . . . . . 4 SECTION 2..0 – INSTALLATION . . . . . .. . . . . . . . . . . . ... . . . .. . . . . .. . . . .. 10 SECTION 5.. . . .. . . . 11 SECTION 6.. . . . . .. . . . . . . .0 – DISASSEMBLY . . . . . . . . . . . . .. .. . . . . . . . . . . . . . . . . . .. ..... . . . . .. . . .. . . . . . . . . . 6 SECTION 3. . . . . .. . . . . .. . . . . . .. . . . . . . . . . . . . . . . . . . . . . .. . . 2 SECTION 1. . . . . . . . . . . . . . . . .. . . . . .. . . . .Operator’s Manual R PAGE 3 K20-5000 Pulsation Dampener CONTENTS PAGE Preface . . . . . . . . . . .. .0 – PARTS ...0 – PRECHARGE ADJUSTMENTS . . .. . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .0 – MAINTENANCE ... . . . .. . . . . . . .. . . . . . . . .0 – ASSEMBLY . . .. . .. .. .. .. 12 . . . . . .. . . . 8 SECTION 4. . . . For those applications where higher precharge pressures are required. Install one lubricated nut on each stud and tighten one turn at a time until dampener is firmly in place. 3. Precharging is accomplished by connecting one end of the charging hose assembly to a standard commercially available NITROGEN bottle and the other end to the charging valve located at the top of the pulsation dampener (Refer to Figure 1-3). precharge pressure is based on the average operating pressure of the system. Charging Hose Assy. 2. Mounting 1. The discharge dampener should be mounted as close as possible to the discharge port of the pump. Assure that space between dampener and flange is equal. General Precharging Instructions 1. but precharge can be affected by other system parameters. it is advantageous that the dampener be mounted in such a way that the fluid stream is directed towards the fluid opening. Allow pressure to increase in the dampener until dampener pressure gauge reads the specified precharge Horizontal Discharge Dampener Vertical Discharge Dampener Mounting Flange Mounting Flange Discharge Line Nitrogen Bottle Charging Valve CAUTION: Do not attempt to precharge any K-Series pulsation dampener prior to mounting the unit into the pump piping system.PAGE 4 Operator’s Manual R K20-5000 Pulsation Dampener 1. for example.1080 N•m). 6. for example. Install stud bolts in the replaceable bottom plate. a gas booster pump is available. Generally. Precharge Hookup WARNING: ALWAYS PRECHARGE WITH ZERO PRESSURE ON THE SYSTEM AND ALWAYS PRECHARGE WITH NITROGEN. consult qualified Hydril personnel for correct precharging instructions. the use of MWD tools. Slowly open charging valve on dampener. The bottom connection for this K20-5000 is a 4 -1/16” API 5000 RTJ. 4. B. 3. Precharge from a standard commercially available nitrogen bottle equipped with a pressure regulator. A. A. Precharging (NITROGEN ONLY) The correct precharge is vital for maximizing efficiency of the pulsation dampener.800 lb-ft or 980 . If possible. Before precharging the dampener make sure all cover stud nuts are tightened evenly and charging valve and pressure gauge seal nuts are firmly seated on the dampener. Figure 1-2. 2. Haskell International Inc. For these applications. Mounting Options . Open bottle regulator valve until recommended precharge pressure shows on regulator gauge. The charging valve and pressure gauge are located under the valve guard and are exposed by removing the valve guard. 7. Cross tighten nuts to the proper torque (725 . Tee Discharge Line Tee Long Radius Elbow Pump Discharge Flange Pump Discharge Flange Figure 1-1. 5. Position dampener on gasket and mating flange so that the space between flange and bottom connection is totally equal around the circumference. 4.0 INSTALLATION The Hydril K20-5000 Pulsation Dampener should be mounted in the vertical position (refer to Figure 1-1 for mounting options) with the mating flange connection at the bottom. body contact surfaces.Operator’s Manual R PAGE 5 K20-5000 Pulsation Dampener Valve Guard With Lifting Eye Charging Valve Pressure Gauge Cover Plate Diaphragm Diaphragm Stabilizer Body Gasket Bottom Plate Figure 1-3. C. Adjust the precharge pressure as required. Allow the nitrogen gas in the dampener to come to ambient conditions (approximately one-half hour) and recheck the precharge pressure. check system for loose connections and retighten. and studs. cover. If any indications are found. However. Observe carefully for bubbles that indicate leaks. Close the charging valve and tighten. remove charging hose. Precharge Recommendations For normal operating conditions. set the precharge pressure at 50 to 70 percent of the average operating discharge pressure not to exceed 5000 PSI. 8. Dampener is now ready for operation. these precharge settings may shorten diaphragm life. and replace valve guard. D. Leak Detection Apply leak detection fluid at all connections around valve. Remove charging hose. replace dust plug in charging valve. This process will normally take 5 to 15 minutes. . close regulator valve at nitrogen bottle. close valves. and replace valve guard. Dampener gauge and regulator gauge should read the same and be equal to the specified precharge pressure. pressure gauge. The precharge pressure can be as low as 30 percent or as high as 75 percent of system operating pressure. Typical K20-5000 Series Pulsation Dampener pressure. After precharge pressure has stabilized at specified pressure. Then. Remove valve guard. B. Verify cover is attached and all stud nuts are snug. Loosen all cover stud nuts. Set stud nuts and gaskets aside and save for reinstallation. Set aside and save if reusable. If the bottom plate is to be removed for replacement or inspection. b. Remove bottom plate from dampener. consult your nearest Hydril representative. g. Cleaning and Inspection Procedure 1. This would indicate that pressure has not been completely removed from dampener. con- sult your nearest Hydril representative for corrective action. 2. Push bottom of diaphragm down. remove cap screw. Remove socket head cap screws that hold bottom plate in place. Disassembly Procedure Refer to Figure 2-1. Inspect bottom plate for excessive pitting. Remove charging valve and gauge from cover. fold diaphragm or place bar between dampener body and diaphragm below the diaphragm mid-section to assist folding and removal of diaphragm from body. Flush diaphragm body. 5. 4. lock washer and stabilizer plate. remove nuts from studs. Replace if damaged. clean and remove scale and other foreign material. Set aside and save. Mild pitting or scaling can be removed with application of light duty emery cloth. but do not remove. 11. Remove all flange and stud nuts at bottom connection.0 DISASSEMBLY A. Inspect inside of dampener body for excessive pitting. Remove dampener from flange connection. After all pressure is removed from dampener. If dampener is equipped with a stabilizer. Corrosion or wear. Remove stabilizer so the diaphragm may be folded and removed from the body. If these conditions exist. Remove cover 10. Attach valve guard to cover to use as lifting eye. 7.PAGE 6 Operator’s Manual R K20-5000 Pulsation Dampener 2. Attach valve guard to cover plate to use as a lifting eye 9. h. c. d. Open charging valve and bleed off all precharge pressure. Remove gasket and inspect for damage. e. 3. 1. 6. 8. Shut down pumps and remove system pressure from dampener. 3. Make sure the cover plate is not pushing upwards against nuts. 12. . Check for system fluid in gauge and valve ports. Pull neck portion of diaphragm loose from one side of dampener. f. Inside of dampener must be free of burrs and debris. Remove dirt and debris from bottom plate opening. corrosion or wear. If these conditions exist. 2. follow the procedure below: a. CAUTION: System and vessel pressure must be at zero psi before removing charging valve and pressure gauge or loosening cover or flange bolts. Operator’s Manual K20-5000 Pulsation Dampener Valve Guard With Lifting Eye Charging Valve Pressure Gauge Cover Plate Diaphragm Diaphragm Stabilizer Body Gasket Bottom Plate Figure 2-1. Typical K20-5000 Series Pulsation Dampener .Disassembly R PAGE 7 . Take the new diaphragm in the at rest position and roll one side toward the other forming a crude football shape.3570 N•m). H. . Back thread seal nut on valve and thread valve into tapped hole. Tighten to 20 ± 5 lb-ft or 27 ± 7 N•m torque 3. Pull up on neck of diaphragm while pushing diaphragm insert area down. temporarily install hex screw into insert. and lubricated nuts. c. take the following steps: a. Diaphragm Installation 1. After gauge is in position. Position the diaphragm within the neck of the vessel. Install cover plate. Place bottom plate gasket in groove of bottom plate. and hex screw through stabilizer and fasten to diaphragm by attaching hex screw to threaded insert. 4. If the gauge is not facing in the proper direction. Rotate forward if less than a ½ turn is required to position gauge in proper direction b. Back thread seal nut on valve and thread valve into tapped hole 3. Scrape and wire brush all surfaces and completely remove any foreign matter. B. and the pulsation dampener is now ready for use. rust or scale. Apply lubricant to the folded diaphragm and insert it long ways into the body of the dampener as far as possible ( the diaphragm should go over half way into the dampener body). Install socket head cap screws and tighten evenly until bottom plate is snug against body. 7. After valve is in position. . Installation of Pressure Gauge 1. take the following steps: a. 6. Rotate forward if less than a ½ turn is required to position valve in proper direction. 5. G. Cross tighten to the appropriate torque (2530 . F Installation of Charging Valve 1. Bottom Plate Gasket Installation 1. Apply a light coat of a general lubricant (castor oil or equivalent) on diaphragm to aid in installation. Break vacuum at neck by pulling diaphragm slightly away from sealing area. E. rust. .800 lb-ft or 980 1080 N•m. Rotate backward if the previous step is not possible until the gauge is positioned in the proper direction ( ½ turn maximum) c. A thin belt or strap may be helpful in holding this shape. Refer to Figure 3-1 while following the procedure below. tighten seal nut to 20 ± 5 lb-ft or 27 ± 7 N•m torque. Insert bottom plate into body taking care not to pinch gasket and align counter bore holes with tapped holes in body. A. and bottom plate which come into contact with the diaphragm must be cleaned carefully before reassembly. Torque cap screws to 725 . Cross tighten by hand or wrench.0 ASSEMBLY All metal surfaces of the cover plate. lock washer.2630 lb-ft or 3430 . Install pressure gauge so that the face is positioned in such a manner that it will be visible through the valve guard opening 2.2. Fold stabilizer with edge down and insert into diaphragm opening. 2. Rotate backward if the previous step is not possible until the valve is positioned in the proper direction ( ½ turn maximum). 5. studs. 2. b. Fold the remainder of the diaphragm into the vessel and allow it to open inside the body. Stabilizer Installation 1. When stabilizer is used.3. Assemble stabilizer plate. Coat with a light lubricant prior to installation of cover plate to the body. 4. a few turns at a time. 6. and install stabilizer.PAGE 8 Operator’s Manual R K20-5000 Pulsation Dampener 3. NOTE: Make certain that the neck portion of the diaphragm and cover plate is clean and free of any debris. Re-seat diaphragm neck. If the valve is not facing in the proper direction. C. tighten seal nut to 20 ± 5 lb-ft or 27 ± 7 N•m torque. Pull up on hex nut so diaphragm bottom moves up near neck opening. Bottom Plate Installation 1. or scale. Attach valve guard. Pressurize Pulsation Dampener Use precharge instructions in Section 1. Cover Plate Installation 1. until cover is firmly seated on the dampener body. Tighten securely with socket wrench. D. remove hex screw. Tighten to 20 ± 5 ft-lb or 27 ± 7 N•m torque 4. 3. body. Typical K20-5000 Series Pulsation Dampener-Assembly R PAGE 9 .Operator’s Manual K20-5000 Pulsation Dampener Valve Guard With Lifting Eye Charging Valve Pressure Gauge Cover Plate Diaphragm Diaphragm Stabilizer Body Gasket Bottom Plate Figure 3-1. The vessel should be checked periodically for proper precharge and leaks. If the pre-charge pressure is TOO LOW. When properly installed and pre-charged. operating conditions.0 MAINTENANCE A. Until the system pressure exceeds the precharge pressure. . Unless conditions such as ambient temperature. C. or operating temperatures change. Low Precharge Effects 1. thus losing some of the working volume of the gas and reducing dampener efficiency. no dampening will take place. the pulsation dampener will fill with excess fluid. Precharge 1. 3. the diaphragm will bounce on and off the inlet opening which could effect the service life of the diaphragm. the pulsation dampener is virtually maintenance free. B. checking every six months should be sufficient. closing off the fluid inlet. excessive flexing of the diaphragm may cause premature rubber failure at the neck or equator of the diaphragm. 2. High Precharge Effects 1. 2. If the pre-charge is TOO HIGH. During the time the precharge pressure is nearly equal with the system pressure.PAGE 10 Operator’s Manual R K20-5000 Pulsation Dampener 4. Additionally. 2. the diaphragm insert will rest on the bottom of the dampener. 2. Ambient temperature may have increased. B. 4.Operator’s Manual R K20-5000 Pulsation Dampener 5. it may be due to nitrogen leaks through the diaphragm. or replace valve if stem does not close. b. close valve stem. which is usually of a different value. Precharge Low Original precharge may have been to low. Replace gauge if leaks continue. 3. If the dampener will not hold precharge pressure. Tighten loose threads. each time the pump shuts down. 1. If fluid is present. Tighten loose threads. 6. Diaphragm may be trapping pressure (system fluid) when pump is shut down. Release pressure. Check for evidence of fluid at either charging valve or pressure gauge port hole. a. face. Precharge High 1. Installation of a diaphragm stabilizer should cure this condition. Original precharge may have been to high. b. This will be indicated by a higher than normal pressure reading on the gauge. b. a. Check charging valve for leaks. replace diaphragm. 5. Apply leak detection fluid to studs and coverbody contact surfaces. If leaks persist. Check Diaphragm (if all the above fail to find the leak). Check pressure gauge for leaks. See Disassembly and Assembly sections. CAUTION: If it is determined that any items need to be replaced or dampener cover removed. PAGE 11 . remove cover and clean mating surfaces. Reassemble and repeat leak test. Tighten stud nuts. This condition usually occurs when the fluid is highly viscous. 3.0 PRECHARGE ADJUSTMENTS A. Apply leak detection fluid to threads and valve openings. a. and back cover. Check for leaks between cover and body. PLEASE FOLLOW THE DISASSEMBLY AND ASSEMBLY PROCEDURES. Ambient temperature may have decreased. Apply leak detection fluid to threads. 2. CAUTION: Make sure dampener pressure is at zero psig before removing charging valve or pressure gauge. 3111331 3111336 1005206 1005208-07 3111338-01 1005212-07 1005213 1005214 1005215 3116004-5 1900105-20 1005073-02 3108946-19 1920007-02 1920007-05 1900035-15 1900205-20020 1900047-12010 1900061-12 1900096-15062 1900168-5 3103237 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 12 8 4 4 12 1 1 1920006-04 3110796-075 1005447-1 1 1 1 6. . Qty.0 PARTS 6. Guard Drive Screw Stud Bolt. Lock. Hydrogenated Bottom Plate Gasket Diaphragm Stabilizer Stabilizer Plate Stabilizer Screw Hydril Logo Label Lock Washer Charging Valve. Bottom Plate Cap Screw. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 * * * * * * * * Description Body Cover Plate Guard Diaphragm. Charging Valve Nut. Pressure Gauge Nut. Cover Plate Pressure Gauge Tag. 5000 PSI Nameplate Nut.2 Accessories * Charging Hose Pressure Control Hardware Kit Bottom Connection Kit * Contents of Pressure Control Hardware Kit (one-year recommended spare parts list).Operator’s Manual PAGE 12 R K20-5000 Pulsation Dampener 6. Lock. Cover Plate Cap Screw. Hex Head. Caution Part No.1 Pulsation Dampener Parts List (See Figure 6-1) PN 3111330-07011 Item No. Operator’s Manual R PAGE 13 K20-5000 Pulsation Dampener 3 12 15 21 14 18 20 16 2 19 13 9 11 19 22 8 7 10 4 1 5 17 6 Figure 6-1.Cutaway for Part Identification . Typical K20-5000 Series Pulsation Dampener . PAGE 14 Operator’s Manual K20-5000 Pulsation Dampener R R . O.OPERATOR’S MANUAL Operator’s Manual K80-3705 Pulsation Dampener R Pressure Control Equipment SALES HEADQUARTERS: P. Box 60458. Texas 77205 • Telephone: (281) 449-2000 • HYDRIL CSD HOU • FAX: (281) 985-2828 R PAGE 2 . Houston.