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K80-3705 Pulsation Dampener

 
K80-3705 Pulsation Dampener R

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Pressure Control Equipment

K20-5000 Pulsation Dampener

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K20-5000 Pulsation Dampener R

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K20-5000 Pulsation Dampener Complete Assembly Hydril Part No. 3111330-07011

Please contact Hydril Pressure Control Equipment for any assistance or questions concerning the information in this manual. All information contained in this manual is the exclusive property of Hydril Company.

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HYDRIL COMPANY/P.O. BOX 60458/HOUSTON, TEXAS 77205

TELEPHONE: (281) 449-2000/TELEX 168905 HYDRIL CSD HOU/ FAX: (281) 985-2828

©2000 Hydril Company

Printed In The U.S.A., August 2000

All Rights Reserved

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K20-5000 Pulsation Dampener

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K20-5000 Pulsation Dampener R

Hydril makes no warranties of any kind, expressed or implied, including any warranty of mechanical fitness for any particular purpose that the work performed pur- suant to this manual will be free from defects in work- manship or material.

Hydril retains for itself all proprietary rights in and to all designs, engineering details, data and procedures set forth herein. 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.

This manual makes recommendations only. The cus- tomer is at all times responsible for actual disassembly, inspection, re-assembly and testing of the pulsation dampener body. The customer is also solely respon- sible for providing competent and qualified persons; equipment and facilities to perform such operations; and for workmanship and safety.

If at any time the customer is unable to understand the recommendations made in this manual or is unable to follow those recommendations, they should consult the nearest Hydril location.

K20-5000 Pulsation Dampener

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K20-5000 Pulsation Dampener R

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CONTENTS

 

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Preface

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SECTION 1.0 – INSTALLATION

 

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SECTION 2.0 – DISASSEMBLY

 

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SECTION 3.0 – ASSEMBLY

 

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SECTION 4.0 – MAINTENANCE

 

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SECTION 5.0 – PRECHARGE ADJUSTMENTS

 

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SECTION 6.0 – PARTS

 

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K20-5000 Pulsation Dampener

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K20-5000 Pulsation Dampener R

1.0 INSTALLATION

CAUTION:

Do not attempt to precharge any K-Series

pulsation dampener prior to mounting the unit into the pump

piping system.

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. The bottom connection for this K20-5000 is a 4 -1/16” API 5000 RTJ. The discharge dampener should be mounted as close as possible to the discharge port of the pump. If possible, it is advantageous that the damp- ener be mounted in such a way that the fluid stream is directed towards the fluid opening.

  • A. Mounting

    • 1. Install stud bolts in the replaceable bottom plate.

    • 2. Position dampener on gasket and mating flange so that the space between flange and bottom connec- tion is totally equal around the circumference.

    • 3. Install one lubricated nut on each stud and tighten one turn at a time until dampener is firmly in place. Assure that space between dampener and flange is equal.

    • 4. Cross tighten nuts to the proper torque (725 - 800 lb-ft or 980 - 1080 N•m).

      • B. Precharging (NITROGEN ONLY)

The correct precharge is vital for maximizing efficiency of the pulsation dampener. Generally, precharge pressure is based on the average operating pressure of the sys- tem, but precharge can be affected by other system pa- rameters; for example. the use of MWD tools. For these applications, consult qualified Hydril personnel for correct precharging instructions.

Nitrogen Bottle Charging Valve Charging Hose Assy. Figure 1-2. Precharge Hookup
Nitrogen Bottle
Charging Valve
Charging
Hose Assy.
Figure 1-2. Precharge Hookup

WARNING : ALWAYS PRECHARGE WITH ZERO PRESSURE ON THE SYSTEM AND ALWAYS PRECHARGE WITH NITROGEN.

  • A. General Precharging Instructions

    • 1. The charging valve and pressure gauge are located under the valve guard and are exposed by remov- ing the valve guard.

    • 2. 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.

    • 3. Precharging is accomplished by connecting one end of the charging hose assembly to a standard com- mercially available NITROGEN bottle and the other end to the charging valve located at the top of the pulsation dampener (Refer to Figure 1-3).

    • 4. Precharge from a standard commercially available nitrogen bottle equipped with a pressure regulator.

    • 5. For those applications where higher precharge pres- sures are required, a gas booster pump is avail- able; for example, Haskell International Inc.

    • 6. Open bottle regulator valve until recommended precharge pressure shows on regulator gauge.

    • 7. Slowly open charging valve on dampener. Allow pressure to increase in the dampener until damp- ener pressure gauge reads the specified precharge

Horizontal Discharge Vertical Discharge Dampener Dampener Mounting Flange Mounting Flange Discharge Line Long Radius Elbow Tee
Horizontal Discharge
Vertical Discharge
Dampener
Dampener
Mounting Flange
Mounting Flange
Discharge Line
Long Radius Elbow
Tee
Discharge Line
Tee
Pump
Discharge Flange
Pump Discharge Flange

Figure 1-1. Mounting Options

PAGE 4 K20-5000 Pulsation Dampener R 1.0 INSTALLATION CAUTION : Do not attempt to precharge any

K20-5000 Pulsation Dampener

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K20-5000 Pulsation Dampener R

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Valve Guard With Lifting Eye Pressure Charging Valve Gauge Cover Plate Diaphragm Diaphragm Stabilizer Body Gasket
Valve Guard
With Lifting Eye
Pressure
Charging Valve
Gauge
Cover Plate
Diaphragm
Diaphragm
Stabilizer
Body
Gasket
Bottom Plate

Figure 1-3. Typical K20-5000 Series Pulsation Dampener

pressure. This process will normally take 5 to 15 minutes. Dampener gauge and regulator gauge should read the same and be equal to the specified precharge pressure.

  • 8. Close the charging valve and tighten. Then, close regulator valve at nitrogen bottle. Remove charg- ing hose, replace dust plug in charging valve, and replace valve guard.

    • D. Leak Detection

Apply leak detection fluid at all connections around valve, pressure gauge, cover, body contact surfaces, and studs. Observe carefully for bubbles that indicate leaks. If any indications are found, check system for loose connections and retighten. Allow the nitrogen gas in the dampener to come to ambient conditions (approximately one-half hour) and recheck the precharge pressure.

  • C. Precharge Recommendations

For normal operating conditions, set the precharge pres- sure at 50 to 70 percent of the average operating dis- charge pressure not to exceed 5000 PSI. The precharge pressure can be as low as 30 percent or as high as 75

percent of system operating pressure. However, these precharge settings may shorten diaphragm life.

Adjust the precharge pressure as required. After precharge pressure has stabilized at specified pressure, close valves, remove charging hose, and replace valve guard. Damp- ener is now ready for operation.

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K20-5000 Pulsation Dampener

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K20-5000 Pulsation Dampener R
  • 2.0 DISASSEMBLY

  • A. Disassembly Procedure

Refer to Figure 2-1.

  • 1. Shut down pumps and remove system pressure from dampener.

  • 2. Remove valve guard.

  • 3. Open charging valve and bleed off all precharge pressure. CAUTION: System and vessel pressure must be at zero psi before removing charging valve and pressure gauge or loosening cover or flange bolts.

  • 4. Remove charging valve and gauge from cover.

  • 5. Check for system fluid in gauge and valve ports.

  • 6. Loosen all cover stud nuts, but do not remove. Make sure the cover plate is not pushing upwards against nuts. This would indicate that pressure has not been completely removed from dampener.

  • 7. After all pressure is removed from dampener, re- move nuts from studs.

  • 8. Attach valve guard to cover plate to use as a lifting eye

  • 9. Remove cover

    • 10. If dampener is equipped with a stabilizer, remove cap screw, lock washer and stabilizer plate. Re- move stabilizer so the diaphragm may be folded and removed from the body.

    • 11. Pull neck portion of diaphragm loose from one side of dampener. Push bottom of diaphragm down, fold diaphragm or place bar between dampener body and diaphragm below the diaphragm mid-section to assist folding and removal of diaphragm from body.

    • 12. If the bottom plate is to be removed for replace- ment or inspection, follow the procedure below:

      • a. Verify cover is attached and all stud nuts are snug.

      • b. Attach valve guard to cover to use as lifting eye.

      • c. Remove all flange and stud nuts at bottom con- nection.

      • d. Remove dampener from flange connection. Set stud nuts and gaskets aside and save for rein- stallation.

      • e. Remove dirt and debris from bottom plate open- ing.

      • f. Remove socket head cap screws that hold bot- tom plate in place. Set aside and save.

      • g. Remove bottom plate from dampener. Remove gasket and inspect for damage. Set aside and save if reusable. Replace if damaged.

      • h. Inspect bottom plate for excessive pitting, cor- rosion or wear. If these conditions exist, con-

sult your nearest Hydril representative for cor- rective action.

B. Cleaning and Inspection Procedure

  • 1. Flush diaphragm body, clean and remove scale and other foreign material.

  • 2. Inspect inside of dampener body for excessive pit- ting. Corrosion or wear. If these conditions exist, consult your nearest Hydril representative.

  • 3. Mild pitting or scaling can be removed with applica- tion of light duty emery cloth. Inside of dampener must be free of burrs and debris.

K20-5000 Pulsation Dampener

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Valve Guard With Lifting Eye Pressure Charging Valve Gauge Cover Plate Diaphragm Diaphragm Stabilizer Body Gasket
Valve Guard
With Lifting Eye
Pressure
Charging Valve
Gauge
Cover Plate
Diaphragm
Diaphragm
Stabilizer
Body
Gasket
Bottom Plate

Figure 2-1. Typical K20-5000 Series Pulsation Dampener - Disassembly

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K20-5000 Pulsation Dampener

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K20-5000 Pulsation Dampener R

3.0 ASSEMBLY

All metal surfaces of the cover plate, body, and bottom plate which come into contact with the diaphragm must be cleaned carefully before reassembly. Scrape and wire brush all surfaces and completely remove any for- eign matter, rust or scale. Refer to Figure 3-1 while following the procedure below.

NOTE: Make certain that the neck portion of the diaphragm and cover plate is clean and free of any debris, rust, or scale. Coat with a light lu- bricant prior to installation of cover plate to the body.

  • A. Bottom Plate Gasket Installation

    • 1. Place bottom plate gasket in groove of bottom plate.

      • B. Bottom Plate Installation

        • 1. Insert bottom plate into body taking care not to pinch gasket and align counter bore holes with tapped holes in body. Install socket head cap screws and tighten evenly until bottom plate is snug against body. Torque cap screws to 725 - 800 lb-ft or 980 - 1080 N•m.

          • C. Diaphragm Installation

            • 1. Apply a light coat of a general lubricant (castor oil or equivalent) on diaphragm to aid in installation.

            • 2. Pull up on neck of diaphragm while pushing dia-

phragm insert area down. .3. Take the new diaphragm in the at rest position and roll one side toward the other forming a crude foot-

ball shape.

A thin belt or strap may be helpful in

holding this shape.

  • 4. 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).

  • 5. Fold the remainder of the diaphragm into the ves- sel and allow it to open inside the body.

  • 6. Position the diaphragm within the neck of the ves- sel.

    • D. Stabilizer Installation

      • 1. When stabilizer is used, temporarily install hex

screw into insert. .2. Break vacuum at neck by pulling diaphragm slightly

away from sealing area.

  • 3. Pull up on hex nut so diaphragm bottom moves up near neck opening.

  • 4. Re-seat diaphragm neck, remove hex screw, and install stabilizer.

  • 5. Fold stabilizer with edge down and insert into dia- phragm opening.

  • 6. Assemble stabilizer plate, lock washer, and hex screw through stabilizer and fasten to diaphragm by attaching hex screw to threaded insert.

  • 7. Tighten securely with socket wrench.

    • E. Cover Plate Installation

      • 1. Install cover plate, studs, and lubricated nuts. Cross tighten by hand or wrench, a few turns at a time, until cover is firmly seated on the dampener body. Cross tighten to the appropriate torque (2530 - 2630 lb-ft or 3430 - 3570 N•m).

F

Installation of Charging Valve

  • 1. Back thread seal nut on valve and thread valve into tapped hole.

  • 2. Tighten to 20 ± 5 lb-ft or 27 ± 7 N•m torque

  • 3. If the valve is not facing in the proper direction, take the following steps:

    • a. Rotate forward if less than a ½ turn is required to position valve in proper direction.

    • b. Rotate backward if the previous step is not possible until the valve is positioned in the proper direction ( ½ turn maximum).

    • c. After valve is in position, tighten seal nut to 20 ± 5 lb-ft or 27 ± 7 N•m torque.

  • G. Installation of Pressure Gauge

    • 1. Install pressure gauge so that the face is positioned in such a manner that it will be visible through the valve guard opening

    • 2. Back thread seal nut on valve and thread valve into tapped hole

    • 3. Tighten to 20 ± 5 ft-lb or 27 ± 7 N•m torque

    • 4. If the gauge is not facing in the proper direction, take the following steps:

      • a. Rotate forward if less than a ½ turn is required to position gauge in proper direction

      • b. Rotate backward if the previous step is not possible until the gauge is positioned in the proper direction ( ½ turn maximum)

      • c. After gauge is in position, tighten seal nut to 20 ± 5 lb-ft or 27 ± 7 N•m torque.

  • H. Pressurize Pulsation Dampener

Use precharge instructions in Section 1. Attach valve guard, and the pulsation dampener is now ready for use.

K20-5000 Pulsation Dampener

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Valve Guard With Lifting Eye Pressure Charging Valve Gauge Cover Plate Diaphragm Diaphragm Stabilizer Body Gasket
Valve Guard
With Lifting Eye
Pressure
Charging Valve
Gauge
Cover Plate
Diaphragm
Diaphragm
Stabilizer
Body
Gasket
Bottom Plate

Figure 3-1. Typical K20-5000 Series Pulsation Dampener-Assembly

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K20-5000 Pulsation Dampener

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4.0 MAINTENANCE

  • A. Precharge

    • 1. When properly installed and pre-charged, the pul- sation dampener is virtually maintenance free.

    • 2. The vessel should be checked periodically for proper precharge and leaks. Unless conditions such as ambient temperature, operating conditions, or operating temperatures change, checking every six months should be sufficient.

      • B. Low Precharge Effects

        • 1. If the pre-charge pressure is TOO LOW, the pulsa- tion dampener will fill with excess fluid, thus losing some of the working volume of the gas and reduc- ing dampener efficiency.

        • 2. Additionally, excessive flexing of the diaphragm may cause premature rubber failure at the neck or equa- tor of the diaphragm.

          • C. High Precharge Effects

            • 1. If the pre-charge is TOO HIGH, the diaphragm in- sert will rest on the bottom of the dampener, clos- ing off the fluid inlet.

            • 2. Until the system pressure exceeds the precharge pressure, no dampening will take place.

            • 3. During the time the precharge pressure is nearly equal with the system pressure, the diaphragm will bounce on and off the inlet opening which could effect the service life of the diaphragm.

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  • 5.0 PRECHARGE ADJUSTMENTS

  • A. Precharge Low

    • 1. Original precharge may have been to low.

    • 2. Ambient temperature may have decreased.

    • 3. Check charging valve for leaks.

      • a. Apply leak detection fluid to threads and valve openings.

      • b. Tighten loose threads, close valve stem, or re- place valve if stem does not close.

  • 4. Check pressure gauge for leaks.

    • a. Apply leak detection fluid to threads, face, and back cover.

    • b. Tighten loose threads. Replace gauge if leaks continue.

  • 5. Check for leaks between cover and body.

    • a. Apply leak detection fluid to studs and cover- body contact surfaces.

    • b. Tighten stud nuts. If leaks persist, remove cover and clean mating surfaces. Reassemble and repeat leak test.

  • 6. Check Diaphragm (if all the above fail to find the leak). If the dampener will not hold precharge pres- sure, it may be due to nitrogen leaks through the diaphragm. Check for evidence of fluid at either charging valve or pressure gauge port hole. CAU- TION: Make sure dampener pressure is at zero psig before removing charging valve or pres- sure gauge. If fluid is present, replace diaphragm. See Disassembly and Assembly sections.

    • B. Precharge High

      • 1. Original precharge may have been to high.

      • 2. Ambient temperature may have increased. Release pressure.

      • 3. Diaphragm may be trapping pressure (system fluid) when pump is shut down. This will be indicated by a higher than normal pressure reading on the gauge, which is usually of a different value, each time the pump shuts down. This condition usually occurs when the fluid is highly viscous. Installation of a diaphragm stabilizer should cure this condition. CAUTION: If it is determined that any items need to be replaced or dampener cover removed, PLEASE FOLLOW THE DISASSEMBLY AND AS- SEMBLY PROCEDURES.

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    K20-5000 Pulsation Dampener

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    6.0 PARTS

    6.1 Pulsation Dampener Parts List (See Figure 6-1) PN 3111330-07011

    Item No. Description Part No. Qty. 1 3111331 1 2 3111336 1 3 1005206 1 4
    Item
    No.
    Description
    Part No.
    Qty.
    1
    3111331
    1
    2
    3111336
    1
    3
    1005206 1
    4
    1005208-07
    1
    *
    5
    3111338-01
    1
    *
    6
    7
    Body
    Cover Plate
    Guard
    Diaphragm, Hydrogenated
    Bottom Plate
    Gasket
    Diaphragm Stabilizer
    Stabilizer Plate
    Stabilizer Screw
    1005212-07
    1
    1005213
    1
    *
    8
    1005214
    1
    *
    *
    9
    1005215
    1
    10
    Hydril Logo Label
    3116004-5
    2
    11
    Lock Washer
    1900105-20
    1
    *
    12
    Charging Valve, 5000 PSI
    1005073-02
    1
    *
    13
    Nameplate
    3108946-19
    1
    14
    Nut, Lock, Pressure Gauge
    1920007-02
    1
    15
    Nut, Lock, Charging Valve
    1920007-05
    1
    16
    Nut, Hex Head, Cover Plate
    1900035-15
    12
    17
    Cap Screw, Bottom Plate
    1900205-20020
    8
    18
    Cap Screw, Guard
    1900047-12010
    4
    19
    Drive Screw
    1900061-12
    4
    20
    Stud Bolt, Cover Plate
    1900096-15062
    12
    21
    Pressure Gauge
    1900168-5
    1
    *
    22
    Tag, Caution
    3103237 1
    6.2
    Accessories
    Charging Hose
    Pressure Control Hardware Kit
    Bottom Connection Kit
    1920006-04
    1
    3110796-075
    1
    *
    1005447-1
    1
    *
    Contents of Pressure Control Hardware Kit (one-year recommended spare parts list).

    K20-5000 Pulsation Dampener

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    3 12 15 21 14 18 20 16 2 19 13 9 11 19 22 8
    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. Typical K20-5000 Series Pulsation Dampener - Cutaway for Part Identification

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    K80-3705 Pulsation Dampener

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    K80-3705 Pulsation Dampener R R Pressure Control Equipment SALES HEADQUARTERS: P.O. Box 60458, Houston, Texas 77205
     
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    Pressure Control Equipment

    SALES HEADQUARTERS: P.O. Box 60458, Houston, Texas 77205 • Telephone: (281) 449-2000 • HYDRIL CSD HOU • FAX: (281) 985-2828

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