WEIR LGE PROCESS

Weir LGE Process Project Number 10079

Hull numbers 2489, 2490 & 2501

Vendor Documentation, Level Indicators

Document Number 10079-CV-LC-001-00

04

03

02

Material list revised to include

01 C. Ritchie C. Bennie B. Roeling 01 Feb 2012
vent gas cooler level indicators
First issue
00 C. Ritchie A. Smith B. Roeling 01 Sep 2011
** FOR INFORMATION ONLY **

Revision Prepared Checked Approved Date Description

WEIR LGE PROCESS

Document Issue
Document Description Rev. Rev.
Number Date
September
Drawing: reflex gauge series 500 large bore 198-15419 -
2011
September
Parts list: reflex gauge series 500 139SS-6-15419 -
2011
September
Drawing: model number 16 valve V16SSUVF-15419 -
2011
January
Drawing: reflex gauge series 500 large bore 198-15487 - 01
2012
January
Parts list: reflex gauge series 500 large bore 139SS-9-15487 - 01
2012
January
Drawing: model number 16 valve V16SSUVF-15487 - 01
2012
Installation, maintenance and operating instructions:
M1 03 -
liquid level indicators and gauges
February
Drawing: reflex welding pad gauge 155-15486 - 01
2012
Installation and maintenance instructions:
- - - 01
welding pad level gauges

Material list EL-LC-001-00 - - 01

Item Qty Tag no Model
1 1 LI-2146 19 RLF 500
2 1 LI-2246 19 RLF 500
3 1 LI-2346 19 RLF 500
4 1 LI-2446 19 RLF 500

5 1 LI-2146 19 RLF 500

6 1 LI-2246 19 RLF 500
7 1 LI-2346 19 RLF 500
8 1 LI-2446 19 RLF 500

9 1 LI-2146 19 RLF 500

10 1 LI-2246 19 RLF 500
11 1 LI-2346 19 RLF 500
12 1 LI-2446 19 RLF 500
 SIMCO ENGINEERS LIMITED
MONKSWAY, BEDE INDUSTRIAL ESTATE,
JARROW, TYNE AND WEAR, NE32 3HJ, ENGLAND.
TEL NO. (0191) 4280999 FAX NO. (0191) 4280008
EMAIL : sales@simco-engineers.com

LIQUID LEVEL INDICATORS AND GAUGES

INSTALLATION, MAINTENANCE AND

OPERATING INSTRUCTIONS

Document : M1 Issue 3 Approved by : 1 of 9

INSTALLATION, MAINTENANCE AND OPERATING INSTRUCTIONS

INSTALLATION

TO AVOID IMPOSING PIPING STRAINS ON THE GAUGE AND CHAMBER, CONNECT AND MOUNT THE
GAUGE SO THAT IT DOES NOT SUPPORT THE PIPING .

DIFFERENTIAL THERMAL EXPANSIONS BETWEEN THE VESSEL AND GAUGE CAN IMPOSE SEVERE
MECHANICAL LOADS ON THE GAUGE – ESPECIALLY IF THE VESSEL CONTAINS HOT OR CRYOGENIC
LIQUIDS. TO PREVENT THESE, INSTALL AN EXPANSION LOOP BETWEEN GAUGE AND VESSEL OR
USE A REASONABLY LONG RUN OF PIPING.

SUPPORT BRACKETS SHOULD BE CONSIDERED FOR GAUGES OVER FOUR FEET IN LENGTH OR OVER
45KG IN WEIGHT , ESPECIALLY WHEN THE GAUGE IS EXPOSED TO VIBRATION. T HESE SUPPORT
BRACKETS WILL PREVENT OVERLOADING THE CONNECTING VALVES AND PIPING AND PREVENT
DAMAGE TO THE GAUGE FROM EXCESSIVE VIBRATION.

EVEN THE FINEST GLASS MAY OCCASIONALLY BREAK UNEXPECTEDLY. ALWAYS PROVIDE
SHUTOFF VALVES BETWEEN GAUGE AND VESSEL TO REDUCE FLUID LOSS IF THE GLASS FAILS OR
THE GASKET BLOWS. WE RECOMMEND SIMCO BALL CHECK VALVES, WHICH PERMIT MANUAL
OPERATION AND ALSO PROVIDE QUICK AUTOMATIC SHUTOFF IF GAUGE GLASS FAILURE SHOULD
OCCUR.

OPERATION

CHECK TORQUE SETTINGS BEFORE THE GAUGE IS COMMISSIONED FOLLOWING THE

INSTRUCTIONS ON PAGE 5.

ALWAYS WARM UP THE GAUGE SLOWLY WHEN IT IS USED WITH A VESSEL CONTAINING HOT
FLUID. CRACK OPEN THE SHUTOFF VALVES CAREFULLY, AND WAIT UNTIL THE GAUGE IS FULLY
WARMED UP BEFORE OPENING THEM COMPLETELY .

DURING SYSTEM SHUT DOWN, IT IS BEST TO LEAVE THE SHUTOFF VALVES OPEN THE GAUGE
THEN COOLS AND DEPRESSURIZES ALONG WITH THE SYSTEM.

INSPECTION

INSPECT THE GLASS REGULARLY FOR ANY SIGNS OF CLOUDING OR ETCHING. IN NEW
PROCESSES, THE GLASSES SHOULD BE INSPECTED DAILY UNTIL THE NEED FOR REPLACEMENT
BECOMES APPARENT; THIS WILL HELP ESTABLISH THE ROUTINE INSPECTION CYCLE.

DOCUMENT : M1 ISSUE 3 2 OF 9
 INSTALLATION, MAINTENANCE AND OPERATING INSTRUCTIONS

ANYTHING THAT GLISTENS BRIGHTLY SHOULD BE LOOKED AT CLOSELY. ANY VISIBLE SCRATCH
WHICH GLISTENS OR ANY STAR-SHAPED OR CRESCENT-SHAPED MARK THAT GLISTENS IS CAUSE
FOR REPLACEMENT . IF INNER SURFACE APPEARS CLOUDY OR ROUGHENED AND WILL NOT
RESPOND TO CLEANING PROCEDURES , THIS IS EVIDENCE OF CHEMICAL ATTACK AND IF SEVERE IS
CAUSE FOR REPLACEMENT.

MAINTENANCE

THE CUTAWAYS (SEE SHEET 9) SHOW THE BASIC ARRANGEMENTS FOR REFLEX AND
TRANSPARENT GAUGES .

SIMCO GAUGES ARE MOULDED BOROSILICATE GLASS, TOUGHENED TO INCREASE ITS MECHANICAL
STRENGTH. THIS GLASS HAS A LOW COEFFICIENT OF THERMAL EXPANSION AND IS MORE
RESISTANT TO THERMAL SHOCK THAN OTHER GLASSES. NEVERTHELESS , LIKE ANY GLASS IT IS
MUCH STRONGER IN COMPRESSION THAT IT IS IN TENSION; YOU SHOULD BE CAREFUL NOT TO
IMPOSE ANY BENDING ON THE GLASS OR SET UP ANY LOCAL STRESSES . THE FOLLOWING POINTS
SHOULD BE OBSERVED TO ENSURE LONG LIFE : -

RECEIVING AND STORING

UPON RECEIVING GLASS COMPONENTS, INSPECT CONTAINERS FOR SHIPPING DAMAGE. KEEP
GLASSES IN ORIGINAL BOXES UNTIL READY FOR USE . IF GLASS IS TO BE INSPECTED, UNPACK
CAREFULLY, AVOIDING BUMPING OR SLIDING POLISHED FACE ACROSS ANY OTHER OBJECT
(INCLUDING WORKBENCHES).

CHECK WITH MAINTENANCE SUPERVISOR AND ENGINEER FOR THE CORRECT GLASS TO BE USED
IN THE LEVEL GAUGE . CHECK BOX AND GLASS LABELS OR MARKING AGAINST THE EQUIPMENT
PRESSURE AND TEMPERATURE RATINGS.

THE GLASSES, GASKETS AND CUSHIONS SHOULD NOT BE RE -USED, EVEN WHEN THEY APPEAR IN
PERFECT CONDITION. REPLACE THEM WITH NEW ONES. CHIPPED OR SCRATCHED GLASS
SHOULD NOT BE USED, BECAUSE SUCH DEFECTS BECOME POINTS OF HIGH STRESS
CONCENTRATION .

EVEN THOUGH A USED GLASS MAY LOOK PERFECT , IT IS NOT AS RELIABLE AS A NEW ONE. BEST
PRACTICE IS ALWAYS TO USE A NEW GLASS. USED GLASSES ARE POOR SAFETY RISKS.

DOCUMENT: M1 ISSUE 3 3 OF 9
 INSTALLATION, MAINTENANCE AND OPERATING INSTRUCTIONS

THE GLASS SHOULD BE SEATED ON A FLAT SURFACE WITH A SUITABLE GASKET ON THE SEATING
SURFACE TO AVOID SUBJECTING THE GLASS TO STRESS CONCENTRATIONS , WHICH RESULT FROM
POOR LOADING. IT SHOULD BE CLAMPED IN PLACE WITH A FLAT COVER PLATE THAT IS
UNIFORMLY LOADED, AS DESCRIBED IN REASSEMBLY PROCEDURES BELOW.

THE GLASS SHOULD NOT BE IN CONTACT WITH ANY METAL SURFACES; IN SERVICE ,
TEMPERATURE DIFFERENCES AT POINTS OF CONTACT WILL SET UP HIGH LOADINGS AND MAY
BREAK THE GLASS.

USE GASKETS AS FOLLOWS: ALL GAUGES – 1.5MM THICKNESS, UNLESS OTHERWISE SPECIFIED.

FOR TRANSPARENT GAUGES USED IN STEAM SERVICE-PROTECT THE GLASS FROM STEAM EROSION
BY INSERTING A MICA SHIELD BETWEEN GLASS AND GASKET ON THE LIQUID SIDE. (FOR SPECIAL
PROTECTIVE DEVICES AND PROCEDURES FOR CRYOGENIC AND CORROSIVE CHEMICAL
APPLICATIONS, SEE SPECIAL APPLICATIONS).

TO AVOID LEAKAGE AND STRESSES ON THE GLASS, WE RECOMMEND THAT YOU USE THESE
PROCEDURES :

BEFORE REASSEMBLING, CLEAN GAUGE CHAMBER FACES THOROUGHLY WITH A SOFT METAL
SCRAPER (PREFERABLY BRASS). BE SURE ALL BURRS AND PIECES OF OLD GASKET ARE REMOVED,
SINCE THEY CAUSE LOW GASKET COMPRESSION AND LEAKAGE .

LOCATE THE GLASS CENTRALLY IN SEAT AND COVER TO AVOID GLASS-METAL CONTACT AT THE
ENDS OR SIDES. T HIS IS BEST DONE WITH THE GAUGE HORIZONTAL ON A BENCH. IF IT MUST
BE REASSEMBLED IN A VERTICAL POSITION, USE A SMALL STRIP OF GASKET MATERIAL AS A
SPACER AT THE TOP AND BOTTOM OF THE GLASS; THE SKETCH SHOWS HOW. THIS WILL
PREVENT CONTACT OF GLASS WITH METAL DURING ASSEMBLY AND IN SERVICE . (SEE FIG 1 ON
SHEET 7)
WITH A TORQUE WRENCH REPLACE THE GAUGE COVERS AS FOLLOWS:

A. CLEAN BOLT AND NUT THREADS AND APPLY LIGHT OIL TO THREADS AND THE NUT FACE.
FOR GAUGES OPERATING AT MORE THAN 65 DEGREES C, USE MOLYKOTE OR SIMILAR
MOLYBDENUM DISULFIDE LUBRICANT .

B. TIGHTEN NUTS FINGER -TIGHT IN THE SEQUENCE SHOWN IN THE SKETCH ON PAGE 8, THEN
TIGHTEN WITH A TORQUE WRENCH IN THE SAME SEQUENCE , IN FIVE POUND STAGES; THIS
PROCEDURE PRODUCES EVEN LOADING OF THE GLASS .

DOCUMENT: M1 ISSUE 3 4 OF 9
INSTALLATION, MAINTENANCE AND OPERATING INSTRUCTIONS

CAUTION – WHEN TIGHTENING THE COVER , BE SURE THE GAUGE IS ISOLATED FROM THE
VESSEL. CLOSE VALVES BETWEEN THE PRESSURE VESSEL AND THE GAUGE GLASS AND OPEN THE
VENT OR DRAIN ON THE GAUGE GLASS TO RELIEVE THE PRESSURE .

C. RECOMMENDED FINAL TORQUES ARE;

PROCESS GAUGES

GAUGE SERIES RECOMMENDED RE-TORQUE OF FACTORY ASSEMBLED

GAUGES AT INSTALLATION
RL & TL-500 47.5NM
R & T-1000 54 NM
R & T-2000 68 NM
R & T-3000 81.5 NM

GAUGE SERIES RECOMMENDED TORQUE OF FIELD REASSEMBLED

GAUGES
RL & TL-500 47.5NM
R & T-1000 54 NM
R & T-2000 68 NM
R & T-3000 81.5 NM

TIPS FOR SPECIAL APPLICATIONS

SPRING WASHERS FOR TEMPERATURE EXTREMES

TO AVOID RETORQUING COVER BOLTS IN EXCEPTIONALLY HOT OR COLD APPLICATIONS, USE

SIMCO SPRING WASHERS UNDER THE BOLT HEADS OR NUTS TO MAINTAIN GASKET LOADING. IT
IS BEST TO RETURN THE GAUGE TO THE FACTORY TO ADD SPRING WASHERS , SINCE LONGER
BOLTING IS REQUIRED AND THE CHARACTERISTICS OF THE WASHERS AND THEIR ARRANGEMENTS
ARE IMPORTANT.

DOCUMENT: M1 ISSUE 3 5 OF 9
INSTALLATION, MAINTENANCE AND OPERATING INSTRUCTIONS

PROTECTION FROM CHEMICAL ATTACK

GAUGE GLASSES USED WITH FLUID CORROSIVE TO GLASS REQUIRE KEL-F OR A MICA SHIELD TO
PROTECT THE GLASS. (SHIELDS CANNOT BE USED WITH REFLEX-TYPE GLASS INSERTS). THE
KEL-F SHIELD IS NORMALLY INSTALLED INSTEAD OF A GASKET BETWEEN THE CHAMBER AND
GLASS INSERT. TO IMPROVE THE SEALING PROPERTIES OF THE SHIELD:

A. WITH KEL-F SHIELD INSTALLED INSTEAD OF GASKET, ASSEMBLE THE GAUGE AND TORQUE
THE COVER BOLTS AS DESCRIBED UNDER REASSEMBLY.
B. LET THE GAUGE SIT WITHOUT PRESSURE FOR 10 TO 12 HOURS , TO ALLOW THE KEL-F TO
COLD FLOW AND IMPROVE SEALING.
C. RETORQUE BOLTS TO ORIGINAL VALUE, FOLLOWING THE SAME SEQUENCE AS BEFORE.
D. HYDROSTATICALLY TEST THE GAUGE FOR SEAL LEAKS . IF NECESSARY, REPEAT STEPS B AND
C (SEVERAL REPETITIONS MAY BE REQUIRED).

LOW TEMPERATURE SERVICE

INSTALLATION

A NON -FROSTING EXTENSION MAY BE INSTALLED ON THE SERIES 500, 1000, 2000 AND 3000
GAUGES. IN EFFECT, THE EXTENSION INCREASES THE DISTANCE FROM THE GLASS FACE TO
CRYOGENIC FLUID, SO THAT THE FACE REMAINS WARM ENOUGH TO PREVENT FROSTING.

UNIFORMLY INSULATE THE GAUGE SO THAT ALL PARTS REMAIN AT THE SAME TEMPERATURE .
OTHERWISE THERMAL GRADIENTS MAY CAUSE OVERLOADS ON THE GLASS OR MAY RELAX THE
GASKET-CLAMPING LOAD AND CAUSE LEAKS .

OPERATION

TO PREVENT THERMAL SHOCK, BRING THE GAUGE INTO SERVICE GRADUALLY; CRACK THE
SHUTOFF VALVES TO PREVENT A COLD SURGE OF LIQUID INTO THE GAUGE , AND DO NOT OPEN
THEM WIDE UNTIL THE GAUGE HAS TIME TO COOL DOWN. DO NOT ISOLATE THE GAUGE WHEN
COLD; THE FLUID WITHIN WILL WARM UP , THE INTERNAL PRESSURE WILL INCREASE , AND THE
GAUGE MAY BREAK. EITHER LET THE GAUGE WARM UP WITH THE SYSTEM AFTER SHUTDOWN, OR
IF IT MUST BE ISOLATED FROM THE VESSEL, VENT IT TO ATMOSPHERE.

DOCUMENT: M1 ISSUE 3 6 OF 9
INSTALLATION, MAINTENANCE AND OPERATING INSTRUCTIONS

IF YOU MUST RETORQUE AT LOW TEMPERATURES TO STOP LEAKS, RETORQUE THE MINIMUM
AMOUNT REQUIRED FOR THE PURPOSE. THE TORQUE TENDS TO INCREASE AS THE GAUGE
WARMS UP , AND EXCESSIVE TORQUING WHEN COLD MAY OVERLOAD THE GLASS WHEN IT IS
RESTORED TO AMBIENT TEMPERATURES. T HE USE OF SIMCO STAINLESS STEEL SPRING WASHERS
(DESCRIBED ABOVE) MAY SOLVE THIS PROBLEM.

HIGH TEMPERATURE SERVICE (OVER 260 DEGREES C

TO PREVENT DAMAGE FROM HIGH STRESSES RESULTING FROM EXTREME TEMPERATURE

GRADIENTS WITHIN THE GLASS , A MICA SHIELD MAY BE INSTALLED ON THE OUTSIDE OF THE
GLASS. THE SHIELD HAS AN INSULATING EFFECT AND PROTECTS THE OUTER SURFACES OF THE
GLASS FROM THE EFFECTS OF RAPID CHANGES IN AMBIENT TEMPERATURE OR COLD SPRAY.

REPLACEMENT PARTS

IT IS EXTREMELY IMPORTANT TO USE GENUINE SIMCO REPLACEMENT PARTS. THEY CAN BE

OBTAINED FROM OUR FACTORY OR YOUR LOCAL AREA, FROM OUR APPOINTED
REPRESENTATIVE/AGENT.

A FINAL NOTICE

SIMCO LEVEL GAUGES ARE RUGGEDLY DESIGNED AND CONSTRUCTED FOR TROUBLE FREE
SERVICE. IF YOU FOLLOW THE TIPS ON THESE PAGES , YOU SHOULD HAVE NO TROUBLE .

FIG 1

DOCUMENT: M1 ISSUE 3 7 OF 9
DOCUMENT: M1 ISSUE 3 8 OF 9
 simco
Fluid Control Products
SIMCO ENGINEERS LTD.
MONKSWAY, BEDE INDUSTRIAL ESTATE, JARROW
TYNE & WEAR NE32 3HJ ENGLAND
Tel. (0191) 428 0999 Fax. (0191) 428 0008
e-mail: sales@simco-engineers.com:
www.simco-engineers.com

SIMCO ISOLATION VALVES

OPERATING INSTRUCTIONS FOR AUTOMATIC SAFETY BALL CHECK

A STANDARD FEATURE WITH THE SIMCO RANGE OF VALVES IS THE AUTOMATIC BALL
CHECK WHICH INSTANTANEOUSLY SHUTS OFF THE FLOW OF MEDIUM SHOULD THE
GLASS BREAK.

TO ENABLE THE BALL CHECK TO FUNCTION CORRECTLY THE VALVE MUST BE IN THE
FULLY OPEN POSITION WITH THE BALL PUSHER IN THE RETRACTED POSITION AS SHOWN
IN FIG. 2

THE FOLLOWING PROCEDURE SHOULD BE ADOPTED WHEN

STARTING UP.
1. TOP VALVE FULLY OPEN.

2. OPEN BOTTOM VALVE QUARTER OF TURN (90 DEGREES) TO EQUALISE THE PRESSURE
BETWEEN THE VESSEL AND THE LEVEL GAUGE.

3. WHEN THE LEVEL OF THE MEDIUM IN BOTH THE VESSEL AND THE GAUGE ARE IDENTICAL,
THE VALVE CAN BE FULLY OPENED TO ALLOW THE BALL CHECK TO FUNCTION CORRECTLY.
 WEIR LGE PROCESS

Material List

Parent Tag
Description Quantity Rev.
Tag Number Number
Indicator, level
- LI-2109 1
(model 26-RLF-500)
Indicator, level
- LI-2146 1 01
(model 19-RLF-500)
Indicator, level
- LI-2150 1 01
(model 18 RW 1000)
Indicator, level
- LI-2209 1
(model 26-RLF-500)
Indicator, level
- LI-2246 1 01
(model 19-RLF-500)
Indicator, level
- LI-2250 1 01
(model 18 RW 1000)
Indicator, level
- LI-2309 1
(model 26-RLF-500)
Indicator, level
- LI-2346 1 01
(model 19-RLF-500)
Indicator, level
- LI-2350 1 01
(model 18 RW 1000)
Indicator, level
- LI-2409 1
(model 26-RLF-500)
Indicator, level
- LI-2446 1 01
(model 19-RLF-500)
Indicator, level
- LI-2450 1 01
(model 18 RW 1000)