INSTRUCTIONS For Installation and Operation of:

Gýrol® Fluid Drive

Equipment: 315 Class 4 Gýrol Fluid Drive Serial Number(s): 533-431-165-0536 Purchaser: Damodar Valley Corporation Location of Use: Damodar Valley Corporation Chandrapura Thermal Power Station Chandrapura, Bokaro District, Jharkhand India Customer P.O.: CT/CE/T-(M.S.-I)/Blr.(P)/117 Howden Buffalo Order Number: S512972 Howden Buffalo Project Number: 505515 8111 Tireman Avenue Telephone No.: (313) 931-4000 Dearborn, MI 48126 Fax No.: (313) 931-4464

Doc. MN5334311650536 Issue A -03/18/2009

I M P O R T A N T:

SHIPPING STRAP REMOVAL LIFT HOUSING COVER AND REMOVE SHIPPING STRAP FROM ROTOR ASSEMBLY BY LOOSENING STRAP AT TENSION TAKE-UP. IT IS NOT NECESSARY TO REMOVE BRACKETS FROM TANK WALL.

The information in this bulletin covers the installation, operation, and the maintenance of the equipment in the Gýrol Fluid Drive. It is intended for use by operation and maintenance personnel who have the technical knowledge and experience to apply proper safety and operation practices. The engineering Department of The Howden Buffalo Company will be glad to provide further information upon request.

TABLE OF CONTENTS: SECTION 1 – General Information

GENERAL DESCRIPTION: ......................................................................... - 1 - OPERATIONS.......................................................................................... - 1 - HOUSING................................................................................................. - 1 - ROTATING PARTS.................................................................................. - 2 - OIL PUMP ................................................................................................ - 2 - BEARINGS............................................................................................... - 2 - SHAFTS ................................................................................................... - 2 - SPEED CONTROLLER............................................................................ - 2 - PAINT....................................................................................................... - 2 - TEST ........................................................................................................ - 2 - OIL COOLERS......................................................................................... - 3 -

INSTALLATION INSTRUCTIONS: .............................................................. - 4 - FOUNDATION.......................................................................................... - 4 - ALIGNMENT ............................................................................................ - 4 - OIL COOLER (WATER)........................................................................... - 5 - OIL COOLER (AIR).................................................................................. - 5 - OIL PIPING............................................................................................... - 5 - METERING ORIFICE ............................................................................... - 5 - SPEED CONTROLLER............................................................................ - 6 -

OPERATING INSTRUCTIONS: ................................................................... - 7 - OIL............................................................................................................ - 7 - INITIAL OIL FILLING ............................................................................... - 7 - OIL FILTER .............................................................................................. - 7 - BEARING LUBRICATION........................................................................ - 7 - STARTING UNIT ...................................................................................... - 7 - STOPPING UNIT...................................................................................... - 9 - OIL TEMPERATURE ............................................................................... - 9 - OIL PUMP OPERATING PRESSURES ................................................. - 10 -

MAINTENANCE INSTRUCTIONS:............................................................ - 11 - OIL CHANGE ......................................................................................... - 11 - MAKE-UP OIL ........................................................................................ - 11 - OIL FILTER ............................................................................................ - 11 -

FLUSHING PROCEDURE:........................................................................ - 12 - GENERAL .............................................................................................. - 12 - FLUSHING PREPARATIONS................................................................ - 13 - FLUSHING PROCEDURE...................................................................... - 14 -

RECOMMENDED OILS FOR USE IN GÝROL FLUID DRIVES: ............... - 16 - TROUBLESHOOTING:.............................................................................. - 17 - DISASSEMBLY INSTRUCTIONS: ............................................................ - 18 - RE-ASSEMBLY INSTRUCTIONS: ............................................................ - 20 -

ASSEMBLY OF ROTATING PARTS ..................................................... - 20 - IMPELLER PILLOW BLOCK ONLY ...................................................... - 20 - SPEED CONTROLLER.......................................................................... - 20 - JOURNAL BEARINGS .......................................................................... - 20 -

REPLACEMENT AND SPARE PARTS:.................................................... - 21 - ROTATING PARTS – LIFTING PROCEDURE: ..................................... - 23 - ROTATING PARTS – EXPLODED VIEW:............................................. - 24 - IMPELLER PILLOW BLOCK:................................................................ - 25 - RUNNER PILLOW BLOCK:................................................................... - 26 - SPEED CONTROLLER ASSEMBLY:.................................................... - 27 -

STORAGE GUIDELINES: ......................................................................... - 28 - GENERAL INFORMATION.................................................................... - 28 - BEFORE STORAGE (Unit not installed or placed in service) ........... - 28 - SHORT TERM STORAGE (Unit not installed or placed in service)... - 29 - LONG TERM STORAGE (Unit not installed or placed in service)..... - 29 - ON-LINE STORAGE .............................................................................. - 30 - ON-LINE STORAGE – ASSOCIATED EQUIPMENT............................. - 31 - ON-LINE STORAGE - STORAGE OPERATIONS AND INSPECTION . - 31 - ON-LINE STORAGE - CONTINUED STORAGE BEYOND ONE YEAR - 32 - PROCEDURE AFTER STORAGE ......................................................... - 32 - START-UP.............................................................................................. - 32 -

SECTION 2 - Drawings GENERAL ARRANGEMENT (078DD11099) ............................................ - 34 - ORDER BILL OF MATERIAL (078AD11101 – Page 1 of 2)..................... - 35 - ORDER BILLOF MATERIAL (Page 2 of 2)............................................... - 36 - CROSS SECTION DRAWING (078D 04134) ............................................ - 37 - EXTERNAL PIPING (078DD11100) .......................................................... - 38 -

SECTION 3 – Auxiliary Components PRESSURE GAUGE TEMPERATURE GAUGE FILTER

SECTION 4 – Test Documents IN-PROCESS PRODUCTION CHECKLIST PILLOW BLOCK ALIGNMENT DATA SHEET IMPELLER BALANCE SHEET IMPELLER BALANCE DATA RUNNER BALANCE SHEET RUNNER BALANCE DATA FLUID DRIVE TEST DATA SHEET FINAL INSPECTION CHECKLIST

SECTION 1 General Information

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GENERAL DESCRIPTION: OPERATIONS

Class 4 “Gýrol” Fluid Drives are designed for heavy duty, adjustable speed power transmission. Each unit includes advanced features of: (1) horizontal sliding speed controller to adjust output speed quickly and accurately; (2) oil film journal bearings; (3) Kingsbury thrust bearing; (4) forced feed bearing lubrication; (5) built in helical gear driven constant displacement pump; (6) heavy welded steel enclosing housing; and (7) piping connections for using water-oil or air-oil coolers. Water-oil coolers are usually mounted on the side of unit but they may be mounted separately. Air-oil coolers are installed separately. All piping is enclosed within the housing except those required for connection to externally mounted oil cooler and cleanable type oil filter. The Fluid Drive tank and cover are split at horizontal shaft centerline. Pillow block bearings are also split on horizontal shaft centerline. The speed controller is adjusted with a horizontal push-pull motion with control rod passing through a stuffing box type of seal at housing. Automatic or manual controls may be used for its operation. A heavy duty sight oil level indicator is mounted on control side of output end of the housing.

HOUSING The rotating parts are enclosed in a welded steel oil tight housing with rigid cross bracing to assure stiffness. The housing is split on shaft horizontal centerline with a removable cover for inspection and maintenance. A compression type seal of oil resistant gasket is used between the tank and cover. Labyrinth grooves and shaft oil slinger ring form a seal at the shaft ends. Oil level in housing indicated on flat gauge mounted on side-wall near scoop control extension. The cleanable type oil filter is externally mounted for maintenance reasons.

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ROTATING PARTS

The rotating parts consist of heat treated cast aluminum rotors with an enclosing casing of steel. Rotors are bolted to the shaft through shaft flanges. The impeller assembly supports inner and outer casing assembly.

OIL PUMP

The oil pump is a constant displacement gear type driven at a constant speed from input shaft by means of helical gears. The necessary oil is delivered by the pump for lubrication of all bearings and also for use in the fluid drive circuit. The driving gear is steel and the driven gear is bronze. The pump drive shaft is supported by unit type journal and thrust bearings.

BEARINGS

The journal bearings are babbitted bronze backed sleeve bearings. A double Kingsbury thrust bearing is supported within impeller, reacting against a thrust plate mounted on runner shaft. This effectively absorbs the hydraulic thrust developed in rotating parts. Bronze thrust rings are located in input shaft pillow block to absorb the thrust of the oil pump helical driving gear. These thrust rings are designed to position the shaft within the unit.

SHAFTS

The input and output shafts are made of S.A.E. 1035 steel, machined and ground to close tolerances.

SPEED CONTROLLER

The horizontal sliding speed controller is supported in brass guide bearings, and operated by a rod extending outside unit through a stuffing box containing oil resistant rubber seals. The external rod end piece is furnished with a drilled hole for attachment of automatic or manual controllers.

PAINT

For external painting the following procedure is recommended. Clean metal thoroughly to remove surface debris. Follow with a chemical wash to remove all traces of foreign material. Prime cleaned surface with a rust inhibitor. A final coat of oil resistant enamel and moderate heat is applied.

TEST

These units are statically and dynamically balanced. After complete assembly and inspection, each unit is given a test run at the rated operating speed.

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OIL COOLERS Two types of oil coolers are used with this unit. One type uses water as a cooling medium. The other type uses air. The type which uses water may be mounted either on the side of the unit or separately from the Fluid Drive. The type which uses air is always mounted separate. When selecting a location for separately mounted cooler, determine the extra pump head necessary to pump oil to and from cooler. The cooler should preferably be located on the same level or below the Fluid Drive unit. When the cooler is located in this manner, the piping loss to and from the cooler must not exceed 5 psi pressure loss. When coolers are mounted above the Fluid Drive unit, the vertical lift must be determined with the piping loss. Total pressure available to overcome both vertical lift and piping loss to and from cooler is 5 psi.

Water Oil Coolers

Standard water oil coolers are shell and tube water coolers with copper tubes, brass alloy tube sheets, brass alloy shells, and cast iron bonnets. Coolers with other materials are available if required. Provisions are made for installation of zinc corrosion arresters when required.

Air Oil Coolers

Air oil coolers consist of finned tube coils with fans to either draw or blow air. Both coils and fans are enclosed in a steel casing.

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INSTALLATION INSTRUCTIONS: FOUNDATION

“Gýrol” Fluid Drives must be mounted on substantial foundations. A steel sub-base with a spring constant of 2 X 106

lbs. per inch, filled with concrete, or equivalent, and extending under the driving machine and the Fluid Drive unit, is desirable. When mounted on a steel sub-base, it is recommended that holes in the sub-base be located from the unit after it has been aligned with the other equipment. If a steel sub-base is not used, sole plates with machined pads should be grouted into the top of the concrete foundation. When aligning flexible couplings on the driving and driven equipment, allowance for expansion or rise in the Fluid Drive centerline height should be as listed in table.

Centerline Height

Thermal Rise

Centerline Height

Thermal Rise

25” .010” 45” .017” 27” .011” 47” .018” 29” .011” 49” .019” 31” .012” 51” .020” 33” .013” 53” .021” 35” .014” 55” .021” 37” .014” 57” .022” 39” .015” 59” .023” 41” .016” 61” .024” 43” .017” 63” .025”

CL4- T001

ALIGNMENT

The following steps must be followed to insure proper alignment. Pay particular attention to Step 4. 1. Subtract the rise that will occur in driven equipment from that of the

fluid drive determined from the table above and set the fluid drive lower than the driving and driven equipment by this amount.

2. Flexible couplings, if included in order, should be installed prior to

aligning fluid drive to driving and driven equipment. See flexible coupling manufacturer’s instructions.

3. Align fluid drive to driven machine. Jacking screws are provided for

temporary alignment. Next, align driving machine to fluid drive. Faces of couplings must be parallel and in line within .002" total indicator reading. Use only flat metal shims between fluid drive housing and sub-base.

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4. Alignment must be re-checked when the entire installation is at

Operating temperature. Dowel the fluid drive in place after trial operation proves the alignment is satisfactory.

OIL COOLER (WATER)

Oil coolers are shipped separately from the Fluid Drive and may be mounted either on side of unit or separately. See OPERATING INSTRUCTIONS for further information.

1. Mount oil cooler on side of housing. Do not pull up tight until Step 2 is

completed. 2. Connect oil piping flanged connections. Pull up tight using gaskets

between flanges.

3. Pipe water lines to cooler. See drawings for location and size of water piping.

4. Install pressure gauges in oil piping. It is recommended thermometers be

installed. OIL COOLER (AIR)

Air oil coolers are shipped separately. See Page 3 for further information. They must be installed as close as practical to the Fluid Drive. 1. Install air oil cooler. See drawing for piping diagram. 2. It is recommended that a by-pass valve and line be installed on oil cooler to aid starting in cold weather. This by-pass valve should be set to open at 10 to 20 lbs. greater pressure than the minimum indicated pressure shown in the OIL PUMP section of OPERATING INSTRUCTIONS.

OIL PIPING All oil piping used for installation of separately mounted water or air oil coolers must be thoroughly cleaned inside. It is recommended that piping be picked after welding. It must be free from all scale, dirt, chips, weld spatter or other foreign material. It is recommended that a strainer be used in oil lines during flushing period.

METERING ORIFICE A metering orifice is used in the oil filter line to control quantity of oil passing through oil filter. The orifice size has been selected at the factory and is not to be changed unless advised. (See piping drawing for location.)

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SPEED CONTROLLER The control rod assembly, including the seal assembly, is set at the factory. The fluid drive is shipped with the control rod assembly immobilized by being wired to the housing. Check adjustment of speed controller. (See Re-Assembly Instructions-Speed Controller for adjustment information.)

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OPERATING INSTRUCTIONS: OIL

Oil is not furnished with “Gýrol” Fluid Drive units. A good grade of mineral oil as is used for steam turbine lubrication and having a viscosity of about 150 SSU at 100°F should be used. (See RECOMMENDED OIL LIST section for list of approved oils for use in Fluid Drives.) Remove cover and check to be sure there is no water anywhere in the tank. Clean off slushing compounds if they are present. The quantity of oil required for initial filling of the Fluid Drive will vary with size cooler used. The quantity indicated in the table below will be sufficient to start unit. Additional oil will be required after the Fluid Drive has been operated enough to fill oil cooler and piping.

INITIAL OIL FILLING When feasible, all separately mounted oil coolers and connecting piping should be filled with oil prior to initial starting of the Fluid Drive.

Size Initial Oil Filling

(Gallons)

Size Initial Oil Filling

(Gallons) 171 55 315 105 198 65 366 145 231 70 427 240 270 75 497 310

CL4- T002

OIL FILTER

During initial operating period the handle of the cleanable type oil filter should be turned every fifteen to twenty minutes. After trial run is completed, turning handle once every 12 hours is sufficient.

BEARING LUBRICATION The Fluid Drive units have oil lines from oil filter to the shaft pillow blocks to assure clean bearing lubrication.

STARTING UNIT 1. As a final check before starting the Fluid Drive, remove cover and

make a general inspection for damage due to mishandling. All bolts are should be tight. This may be done at time of initial oil filling.

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IMPORTANT! Remove pipe plugs and/or lube fittings on top of each pillow block and pour two (2) quarts of oil into each bearing housing before starting.

2. Move speed controller to fully declutched position. 3. Start main driving motor and check that it is rotating in the right

direction. When minimum pressure called for in table on page 12 is indicated on “Oil Supply Pressure Gauge,” unit is ready to drive secondary (output shaft).

4. Move speed controller slowly in a speed increase direction until output

shaft begins to turn slowly. Stop movement of speed controller and allow unit to run slowly.

5. Inspect and check equipment to make sure everything is functioning

properly. Allow unit to run slowly until it is warmed up.

IMPORTANT! When oil temperature reaches 130°F, turn on cooling water or cooling fan.

6. Ensure proper cooling:

a. If water oil cooler is used, open water valves to check that water is flowing freely.

b. If air oil cooler is used, start fan to check that air is flowing freely through cooling coil.

7. Move speed controller to fully declutched position and check oil level in

sight oil level indicator. 8. If oil level is below maximum as indicated on drawings, add more oil

through fill hole in housing cover. Do not exceed maximum oil level on oil level indicator.

9. Observe pressure indicated on “Oil Supply Pressure Gauge”, (see

outline drawing). The pressure on this gauge should read amount indicated in the Oil Pump Operating Pressures Table later in this section when oil temperature from cooler is at 130°F. The “Oil Pump Pressure Gauge” will read higher depending on pressure drop through cooler and piping.

If air coolers are used, follow these additional precautions: 1. Procedures as already outlined are to be followed.

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2. When starting unit with air oil cooler in cold weather, check that the by-pass valve on line around the cooler will open at proper pressure.

STOPPING UNIT

Move speed controller to fully declutched position. Shut off main driving motor. Shut off water valves to oil cooler. If an air cooler is used, shut off fan. An alternate method is to shut off main driving motor, then shut off water valves to oil cooler or, if an air oil cooler is used, shut off fan. Before starting unit again, check that speed controller is in the fully declutched position. If controller is not in this position, no harm will be done to the Fluid Drive but driving motor may be overloaded.

OIL TEMPERATURE

During operation of Fluid Drives, oil temperature may safely vary between 60°F min and 160°F max. Accepted normal operating temperature is 135°F leaving cooler. Oil temperatures to cooler above 200°F are considered excessive. Oil temperatures from cooler above 160°F are considered excessive. Water Oil Coolers

They are normally selected to maintain 135°F oil temperature leaving cooler under maximum cooling requirements. The exact leaving oil temperature depends on cleanliness of cooler, entering water temperature and volume of water flowing. Oil temperature may rise to 160°F for short periods without problems. However, if oil temperature leaving cooler exceeds 135°F for a long period of time follow precautions below. 1. Check water supply (volume and entering temperature). 2. If excessive temperature continues, shut off water, remove

bonnets and clean water passages. 3. If excessive temperature continues, tube bundle must be

removed and oil side of tubes cleaned. Air Oil Coolers

They are normally selected to maintain between 130°F and 140°F oil temperature leaving cooler with 100°F air entering cooler. Exact oil leaving temperature results from the balance of commercial cooler sizes and heat loads involved. Occasionally coolers will be furnished for materially higher oil temperatures. There should be no cause for alarm if oil under maximum heat load and inlet air temperature conditions goes as high as 160°F for short periods. However, if leaving oil temperature exceeds 140°F for any considerable period the cooler should be checked. 1. Cleanliness of air passages through coil.

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2. Volume of air flowing.

3. If oil temperature continues to be excessive clean oil side of coil

tubes. OIL PUMP OPERATING PRESSURES

Pressure on “Oil Supply Pressure Gauge” should be as listed in table below. Pressures vary because of Size and RPM. If considerably lower pressures occur, look for pump problems, low oil level, or misplaced orifice plates. The “Oil Pump Pressure Gauge” will read a higher pressure depending on pressure drop through the cooler and piping.

Size Input

RPM Oil Supply Pressure

Size Input RPM

Oil Supply Pressure

171-4 1800 5-10 psi 366S-4 900 9-14psi 171-4 1200 3-8 psi 366-4 1200 7-12 psi 198-4 1800 9-14 psi 366-4 900 10-15 psi 198-4 1200 5-10 psi 366-4 720 9-14 psi

231S-4 1800 14-19 psi 427S-4 1200 19-24 psi 231-4 1800 14-19 psi 427S-4 1000 17-22 psi 231-4 1200 5-10 psi 427S-4 900 17-22 psi 231-4 900 4-9 psi 427S-4 720 16-21 psi

315D-4 1800 14-19 psi 427-4 900 17-22 psi 270-4 1200 7-12 psi 427-4 720 16-21 psi 270-4 900 6-11 psi 427-4 600 15-20 psi

315S-4 1500 12-17 psi 497S-4 900 14-19 psi 315S-4 1200 7-12 psi 497S-4 720 13-18 psi

315-4 1200 10-15 psi 497S-4 600 12-17 psi 315-4 900 9-14 psi 497-4 900 14-19 psi 315-4 720 8-13 psi 497-4 720 13-18 psi

366S-4 1200 10-15 psi 497-4 600 12-17 psi 366S-4 1000 9-14 psi

CL4- T003

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MAINTENANCE INSTRUCTIONS: OIL CHANGE

Under ordinary operating conditions it is necessary to change oil only once a year.

MAKE-UP OIL The Fluid Drive should be free of any leaks. However, during a long period of operation, it may be necessary to add make-up oil to the tank. With the speed controller in fully clutched position (this gives full output speed), check minimum oil level on sight glass. If oil is required, add it through fill hole in housing cover. Oil supplier should be consulted for recommended maintenance procedure. In the absence of suppliers’ recommendations, the following recommendations are given. • Moisture content not to exceed 0.1% maximum. • Oil check schedule:

Normal (185°F tank temperature) Allowable 9 mos. to 15 mos. 12 mos. to 21 mos.

Normal (200°F tank temperature max.) Allowable 1 mos. to 3 mos. 3 mos. to 6 mos.

• Every six (6) months, samples of oil should be taken and tested for

water-acidity. Oil heated to 225°F starts to break down and become acidic. It loses its lubricity and should be replaced if overheated for an extended period.

• Normal turbine practices for replacing or conditioning oil should be

observed or ASTM Standards No. D-95 for water content.

OIL FILTER At regular intervals remove drain plug from bottom of filter tank to drain accumulated dirt. This should be done at regular maintenance shutdown inspection. (If other types of oil filters are used, see maintenance manual.) NOTE: driving motor and fluid drive to be operating smoothly. Re-check after load is brought up to normal operating speed. The normal and allowable vibrations on input and output shafts are as follows:

Normal Shaft Vibration Allowable Shaft Vibration 1 to 3 mils 4 to 5 mils

Transient swings or changes in vibration are normal during changes in scoop position.

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FLUSHING PROCEDURE: GENERAL

Gýrol Fluid Drives with externally mounted oil pumps require that oil carrying pipes, vessels, valves, coolers, etc., to be flushed prior to placing the unit into operation. Since a considerable amount of piping is involved in connecting of pump(s) and cooler(s) to the Fluid Drive, it is essential that circuit and lube oil systems be thoroughly flushed to achieve cleanest possible system. A system is considered clean when no foreign materials such as metal chips, weld spatter, oxide scale, sand, or other debris larger than 250 microns are captured in a temporary strainer. System cleanliness is responsibility of engineer or contractor in charge of flushing.

The Fluid Drive, cooler(s), pump(s), valves and piping furnished by The Howden Fan Company is thoroughly cleaned prior to shipment. Additional cleaning before field flush will only be necessary if contaminated during installation.

Positive displacement pump(s) furnished with the Fluid Drive are designed with close tolerances in pumping elements and can be used during flushing if a temporary 100 mesh Y-strainer is installed in pump suction line. If cooler(s) is (are) not by-passed for flushing it (they) must be protected by a temporary full capacity filter. Strainer and filter must be checked at regular intervals during flush cycle. For reduced flushing time a duplex filter can be installed in system prior to cooler(s) to accomplish on line flushing. If filter cannot be placed before coolers, then installation after coolers will effectively clean system as temporary strainer will trap particles large enough to damage pump(s) and cooler(s). Install a valve in place of cooler drain plug to allow blow down of any material collected at low point. This can be exhausted at regular intervals (every hour after the four hours throughout flush). To achieve the highest rate of flow permanent main pumps can be used to decrease flushing time. Howden Fan Engineering must be notified to insure system back pressure will not be beyond design limitations. DC (auxiliary) pumps should never be used for flush. If carbon steel piping is used or if heavy contamination is present, a professional flushing rig should be used consisting of a suitable 100 mesh strainer, filters, differential pressure gages, valves, and a high capacity centrifugal pump that supplies flush flow at greater than 10 ft./sec. This supplemental flushing pump may be connected to piping system as close to permanent positive displacement pump(s) as possible. It is not intended for permanent pump(s) be used in conjunction with supplemental pump during flushing. When stainless steel piping is used, system pumps must have proper protection. A 100 mesh strainer (.0055 openings) placed before pumps will insure protection of all equipment involved during flush.

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FLUSHING PREPARATIONS

Remove bolts to lift the Fluid Drive cover from lower half of housing. Remove shipping strap. Prepare internal piping for flushing procedure by disconnecting lube oil lines to pillow block(s). Direct oil flow to bottom of housing to prevent entrance of debris-laden oil into lube piping during flushing. Disconnect circuit oil pipe inside housing at flexible pipe coupling. Rotate upper and/or lower pipe(s) to prevent debris-laden oil from entering circuit piping. It is important that internal piping is rearranged as described above to eliminate contamination of bearings and circuit during flush. Remove all orifices, check valves, and instruments in piping system which would impede oil flow or could be damaged due to debris-laden oil velocity during flushing. A pet cock or valve should be added in external piping prior to temporary full flow filter or at gauge location after pump(s) for oil sampling. Prepare equipment lubricated from the Fluid Drive system for flush in accordance with manufacturer’s specifications. Although not required, heating oil during flushing will decrease system warm-up time during cold weather flushes or when oil temperature is lower than 40°F. Heating of flushing oil can be accomplished using one of several different methods. The preferred method it to attach a temporary low pressure steam line to service water side of the Fluid Drive cooler. Steam admitted to cooler(s) must not be more than 5 psig to prevent leakage or damage. Care should be taken to insure oil temperature does not exceed 180°F. Other acceptable methods of heating flushing oil are described below:

Fill cooler(s) with water and bubble with low pressure steam. The cooler must be vented to atmosphere to prevent over pressurization.

Electric heating coils can also be used by wrapping piping or supplying hot water to cooler water ports in place of steam.

If carbon steel piping is used, joints and flanges should be vibrated frequently, either manually or mechanically, during flush to dislodge any scale, weld spatter, or slag that has adhered to piping surfaces. After piping installation has been completed and no further welding, burning, drilling, or tapping of piping or valves, etc., is anticipated, inspect all accessible areas of the Fluid Drive and piping system. Any contamination is to be removed by wiping or vacuuming.

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A good grade of mineral oil such as used for steam turbine operation is used for flushing. Oil is to conform to ISO32 with viscosity of 150 SSU at 100°F. To determine quantity of oil required, use the volume listed in the Instruction Manual plus a calculated estimate of the amount of oil required to fill the system piping.

FLUSHING PROCEDURE

Minimum oil level in the Fluid Drive housing, as specified in the Instruction Manual, must be maintained during flushing so flushing and/or system pump (s) will operate without cavitation. Start supplement oil pump or system (permanent) pump(s) and circulate oil throughout system. If heating, gradually heat oil not exceeding 180°F. Cycle the oil temperature between 60°F and 180°F as rapidly as possible during the warm-up interval. If heat is not used, pump and pipe system resistance will heat oil sufficiently. Carbon steel piping should be vibrated during this heating-up period. This vibration loosens foreign material that has adhered to piping surfaces and welded joints. When using the Fluid Drive cooler(s) for heating oil during flush cycle, do not use cold water to cool the coil. Allow temperature of tube bundles and sheets to cool to oil temperature before applying cold water. Oil circulation should be continued as long as necessary to insure system cleanliness. Flushing period may vary from 4 hours to several days, depending on findings.

A large percentage of foreign material will collect in cooler housings, Fluid Drive housing, filter bodies, and strainers during the first few hours of flush. A temporary valve can be installed in cooler(s) and filter(s) at drain plug location to regularly remove foreign matter. After the first four hours of flushing, take approximately one gallon of oil from combined locations, mark and inspect using particle count criteria the chart below. During this time when there is a pressure drop of 5 psig above initial, across strainer and/or filter, they should be cleaned. When flushing systems having carbon steel piping, deposits of foreign material in the strainer/filter should be cleaned-out periodically to prevent starvation of the oil pump. If there are large amounts of contamination, oil in housing and cooler should be drained and the Fluid Drive housing cleaned with lint free rags and vacuumed before refilling system with clean oil. If contamination is in large amounts, continue oil flush until no evidence of foreign material larger than 250 microns appears in strainers. Oil samples should be taken from a location prior to filters using gauge port or installed tap. Samples should show a descending particle count throughout flush.

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The amount of contaminants from dynamic samples taken at hourly intervals should be at or below listed criteria.

PARTICLE SIZE MAXIMUM PARTICLE SIZE per 100 ML Sample

Greater than 10 microns 250,000 Greater than 20 microns 64,000 Greater than 30 microns 16,000 Greater than 40 microns 4,000 Greater than 50 microns 2,000 Greater than 60 microns 250 Greater than 70 microns None

* 1 micron = 0.0000394 inch 25 micron = 0.001 inch CL4- T004

A cleanable edge-type filter is used on lubrication piping supply lines with spacing of discs at 0.0015 inches or equivalent to 38 microns. Sampling should be checked at hourly intervals after first four hours. Standard ISO 20/17 should be used for cleanliness level of Fluid Drive system. Testing should use 100 ML sample gathered from oil piping prior to filter. When flushing is completed, allow circulation to continue until oil temperature reaches 120°F. When this temperature is reached, remove flushing oil from system. Open drain on cooler(s), filter(s), and Fluid Drive l housing. All temporary equipment used for flushing system must be removed. Piping, valves, orifices, and instrumentation removed prior to flushing must be replaced in original locations. Replace drain plugs in cooler(s), filter(s), and Fluid Drive housing. The Fluid Drive housing and all other accessible surfaces should be manually cleaned with lint free rags to remove all traces of residual oil and foreign material. A full charge of filtered oil of recommended grade should be installed in the system as soon as possible. Flushing oil may be used in drive if it meets ISO32 grade and is filtered before being placed back into system. Replace cover on Fluid Drive and circulate oil to insure all surfaces are protected. Do not over fill. Fill according to instruction manual requirements.

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RECOMMENDED OILS FOR USE IN GÝROL FLUID DRIVES: The following is an example of the General Specifications for Oils for using

in Gýrol Fluid Drives. This oil meets ISO 32, which is petroleum-based. Also included is a partial list of Recommended Manufacturers and brand names or numbers that conforms to this ISO Specification.

General Characteristics (Based on Mobil DTE Oil Light)

Product No. 60014-8 Gravity, API 31.7Specific Gravity 0.871Pour Point 20°F, -7°CFlash Point 395°F, 201°CViscosity: Saybolt Universal Seconds 150/165 SUS @100°F Saybolt Universal Seconds 44 SUS @ 210°FViscosity: Centistokes 28.8/32.0 @ 40°C Centistokes 5.2 @ 100°CViscosity Index (minimum) 95ISO Viscosity Grade 32Color ASTM (maximum) 1.5Neutralization Number 0.20Rust Test (A&B) (ASTM D665-IP135) PassDemulsibility (ASTM 1401) 3ml, max. Pass @ 54°C (130°F) ½ hr. @ 82°C (180°F) 1 hr.

MANUFACTURER OIL BRAND NAME AND NUMBER Amoco Oil Company............... Industrial Oil No. 32, Rykon Oil No. 32 BP PetroleumTurbinol ...........................................T32, Energol HLP HD 32 Chevron U.S.A. Inc...............................GST Oil 32, AW Hydraulic 32 Citgo Petroleum................... Citgo Pacemaker T32, AW Hydraulic 32 Conoco, Inc. ........................ Dectol R & 0 Oil 32, Super Hydraulic 32 Exxon Company, U.S.A. .............................. Teresstic 32, Nuto H 32 E. F. Houghton ................................................... Hydro-Drive HP 150 ICI Corp. ............................................................................. Tribol 771 Keystone .............................................................................. KLC - 10 Lyondell Petrochemical Co. .............................. Duro 32, Duro AW 32 Mobil Oil Corporation...............................................DTE Oil Light, DTE 797 Phillips 66 Company............................. Magnus Oil 32, Magnus A 32 Shell Oil Company............................................. Tellus 32, Turbo T32 Texaco, Inc. ............................ Regal Oil R & O 32, Rando Oil HD 32 Unocal 76 ...............................................Unax AW 32, Turbine Oil 32

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TROUBLESHOOTING:

Excessive oil temperatures may be caused by the following circumstances: 1. Entering cooling water temperature too high. 2. Insufficient quantity of cooling water. 3. Coolers may be air bound and require venting. 4. Cooler water passages may need cleaning. 5. Cooler oil passages fouled or partially blocked. 6. Quantity of cooling oil circulating insufficient.

a. Pump suction restricted due to foreign material in line to pump. b. Loose gaskets or breaks in internal piping of fluid drive.

7. Fluid drive is overloaded. 8. Damaged bearings or insufficient lube pressure. Low oil pressure may be caused by: 1. Dirty oil filters. 2. Restriction in pump suction line. 3. Damaged bearings. 4. Loose gaskets or break in internal lube piping. 5. Defective oil pump. 6. Inadequate oil supply or suction conditions.

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DISASSEMBLY INSTRUCTIONS:

1. Reach through the hole and loosen the set screws in the rotating dust seal (Item 305).

2. Move the rotating dust seal toward the shaft outer end to provide clearance between the shaft seal and the pillow block.

3. Remove the cap screw holding the shaft seals and move the shaft seals toward the shaft ends to clear the pillow block.

4. Remove split flange bolts and housing cover. Do not allow the cover to strike the pressure gauges while lifting. Remove any gauges or switches that protrude above house split flange to prevent accidental damage.

5. Disconnect any pipes that may pass over the shafts at the flexible couple and swing it out of the way.

6. Disconnect the oil lines and sensors (if furnished) from shaft pillow blocks. 7. Remove the cap half of the pillow block bearings. 8. Loosen the set screws in the cast iron thrust collars (Item 216) and move

the collars to clear the lip of the bronze thrust rings. 9. Remove the top half of the split bronze thrust rings (Item 217). 10. Remove the scoop tube (Item 259) from the scoop slide (Item 248). 11. Put nylon straps around both input and output shafts to lift the assembly

from the housing. 12. Remove the pump driven gear from the pump shaft. Complete rotating

parts may be lifted out of the housing. Take steps to protect pump drive gear so that it is not damaged during lifting. NOTE: Prior to lifting rotating parts assembly out of the housing, have a bench type location ready to provide for support during the remainder of disassembly. A hole in bench top will allow rotating parts to rest on bench with output shaft down.

13. Install an eyebolt lifting lug in the flexible coupling end of the input shaft. 14. Using a second chain hoist, lift with eyebolt lifting lug until the shafts are

vertical then lower onto the bench. The top output shaft should pass through the hole in the bench top.

DISASSEMBLY OF KINGSBURY THRUST BEARING 15. Remove cap screws (Item 171). 16. Remove input shaft. Use jack screw tappings tin flange of input shaft. 17. Remove and set aside spacer shim (Item 234) and upper thrust bearing

cage ring (Item 225) if necessary. 18. Remove upper shoe cage (Item 228). Tapped holes are provided for

lifting. 19. Remove six (6) shoes (Item 229). 20. Remove thrust plate retainer (Item 233).

CAUTION: Cap screws must be loosened 1 turn at a time in sequence. This will allow output shaft to move downward until it rests on inner casing.

21. Remove thrust plate (Item 231). Tapped holes are provided to remove this plate.

- 19 -

22. Remove six (6) shoes (Item 229). 23. Remove lower shoe cage (Item 228) and lower thrust bearing cage ring

(Item 225). 24. Remove bolting rign cap screws (Item 174). Be sure to reverse these cap

screws and insert them into same tapped holes on other side of bolting ring. This is necessary to preserve dynamic balance of rotating parts.

25. Remove impeller and casing. Provide a lifting lug to match holes where input shaft is bolted to impeller. Insure that balancing match marks have been plainly identified for assembly purposes.

26. Remove runner and output shaft. Tapped holes are provided for lifting.

- 20 -

RE-ASSEMBLY INSTRUCTIONS: ASSEMBLY OF ROTATING PARTS (REVERSE ABOVE PROCEDURE)

1. Check clearance in Kingsbury thrust bearing by raising and lowering impeller shaft.

2. If required, change spacer shim (Items 234 thru 238 as required) to give

clearance (See ROTATING PARTS EXPLODED VIEW drawing).

IMPELLER PILLOW BLOCK ONLY 1. Position rotating parts assembly to give proper shaft extension on input

and output shaft. Scoop tube should not rub. 2. Install split bronze thrust rings. Pin should fit into slot provided in holding

block. 3. Install cast iron thrust collars. Counter bore should fit over lip of bronze

thrust ring. Shaft must be free of nicks and burrs. 4. Adjust one thrust collar tight against bronze thrust ring and tighten split

bolts and set screws securely. 5. Using feeler gauges between the thrust collar and thrust rings, adjust the

other collar to give a total clearance as shown on Impeller Pillow Block (See IMPELLER PILLOW BLOCK Drawing). Measure clearance at a position below shaft centerline.

6. Rotate shaft slowly to ensure both thrust collars are square on shaft and maintain uniform clearance.

7. Pour 1 quart of oil through radial fill hole in impeller shaft to lubricate Kingsbury thrust bearing. Fill bearing housing with oil. IMPORTANT! Assemble upper half of pillow block bearings. (See IMPELLER PILLOW BLOCK Drawing)

8. Tighten split bolts securely. SPEED CONTROLLER

Adjust travel of scoop tube and slide by means of stop rod and lock nuts on each end of scoop slide. With scoop tube at the fully declutched position, adjust until clearance between scoop tube and outer casing is enough to prevent rubbing. In clutched position scoop tip should overlap eye of casing by ¼” to ½”.

JOURNAL BEARINGS

CAUTION: When assembling impeller and runner pillow block bearings, follow instructions on drawings. Do not bottom set screws in upper half of journal bearings.

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REPLACEMENT AND SPARE PARTS:

ITEM NO.

QTY. REQ’D

DESCRIPTION PART NO.

43 1 HOUSING ACCESS COVER 078AP030761 44 1 RING GASKET 078CP068741 55 1 IMPELLER PILLOW BLOCK ASSEMBLY 078SA01306 65 1 RUNNER PILLOW BLOCK ASSEMBLY 078SA01307 75 •4 JOURNAL BEARING 078PP00078 76 4 DOWEL PIN 5/16” X ½” 000 28632 77 8 HHCS 1”-8UNC X 3” 000 66865 79 4 PIN, TAPER - #9 X 3” 000 25986

127 1 IMPELLER, CASING AND SHAFT 078CS0677710 180 1 RUNNER SHAFT ASSEMBLY 078DS096581 205 1 GASKET, SHEET 000 68098 207 38 HHCS 1/2-13UNC X 2-1/4” LG 000 00162 208 38 HEX NUT 1/2-13UNC 000 00075 210 2 PIN, TAPER #7 X 1-3/4” LG 000 25977 212 1 GASKET, SHEET 000 80755 213 2 PLUG, SQUARE HEAD - 3/8 NPT 000 00955 214 4 SET SCREW 1/2-13UNC X 2” LG. 000 26657 215 4 HEX NUT 1/2-13UNC 000 00075 216 •2 THRUST COLLAR 014PP01102 217 •2 THRUST RING 078PP01455 218 2 HOLDING BLOCK 078P 00119 219 2 SHCS #10-24 X 5/8” LG. 000 28372 220 1 LOCK WASHER, BEARING 069PP00378 221 1 KEY, 3/8” SQUARE 078P 00444 223 2 KEY, 1” SQUARE 000 26457 225 2 BEARING CAGE 078P 00073 227 1 BEARING THRUST 078SA00620 228 •2 THRUST BEARING CAGE 078PP00276 229 •12 THRUST SHOE 078PP00286 230 6 DOWEL PIN 5/16” X 7/8” LG 000 28634 231 •1 THRUST BEARING PLATE 078P 00541 232 1 KEY, 1/2” SQUARE X 1-3/16” 078P 00478 233 •1 THRUST PLATE RETAINER 078BP041945 234 *•1 SHIM, THRUST BEARING 078P 044918 235 *•1 SHIM, THRUST BEARING 078P 044919 236 *•1 SHIM, THRUST BEARING 078P 044920 237 *•1 SHIM, THRUST BEARING 078P 044922 238 *•1 SHIM, THRUST BEARING 078P 044924 239 6 HHCS 1/2-13UNC X 3-1/4” LG 078AP0345950 240 6 WASHER, FLAT – 1/2” HARDENED 000 66964 242 2 SCOOP SLIDE BRACKET 078P 00453 244 4 HHCS 1/2-13UNC X 1-1/2” LG 078AP0345921 245 2 FT. AIRCRAFT SAFETY WIRE 000 67425 246 4 TAPER PIN WITH NUT #5 X 1-1/2” LG 000 25958

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248 1 SCOOP SLIDE 078P02198 250 2 STOP ROD, (SCOOP SLIDE) 078P 00731 251 2 HEX NUT, 7/16-14 000 00073 253 •4 GUIDE, SCOOP SLIDE 078P 02212 254 8 HHCS 5/16-18UNC X 1-3/4” LG 078AP034597 255 3FT. AIRCRAFT SAFETY WIRE 000 67425 259 •1 SCOOP TUBE ASS’Y C.W. ROT. 078CS088081 270 4 HHCS 3/8-16 X 1” LG. 078AP0345911 271 2 FT. AIRCRAFT SAFETY WIRE 000 67425 273 1 CONTROL ROD END 078P 00489 274 1 CLEVIS, ADJUSTABLE 078PP00291 278 1 CONNECTING ROD 078P 02206 279 1 HEX NUT 7/8-14UNC 000 28419 280 1 HEX NUT 5/8-18 000 25759 282 1 COVER, ROD 078P 01089 284 •2 PERFECT OIL SEAL 078PP00246 285 1 GUIDE, ROD 078P 00247 286 2 ROD SEA; PLATE 078P 00248 287 1 GASKET, RING 070PP00690 288 1 COMPANION FLANGE 069PP01315 289 4 HHCS 5/16-18UNC X 2-1/4” LG 000 00133 291 4 FLAT WASHER, HARDENED 5/16” 000 67134 293 1 CLOSE PIPE NIPPLE 1-1/4” X 1-5/8” 000 01189 294 2 PIN TAPER WITH NUT #5 X 2” LG 000 25956 297 2 SHAFT VAPOR SEAL 078P 01033 298 2 SHAFT SEAL 078P 01235 301 24 HHCS 1/2-13 X 1-1/4” LG 000 00156 303 •2 SHAFT SEAL GASKET 078P 01292 305 •2 DUST RING 078P 00559 334 1 GASKET, ACCESS COVER 078CP075461 335 14 HHCS 5/16-18 X 1” LG 000 66842 336 14 FLAT WASHER, HARDENED 5/16” 000 67134 446 •1 DRIVEN GEAR – BRONZE C.W. ROT. 078PP01989 448 •1 DRIVE GEAR – STEEL C.W. ROT. 078PP01612

SYMBOL KEY:

• RECOMMENDED SPARE PART * THE LAST TWO DIGITS IN THE PART NUMBER DESIGNATE THE

GAUGE THICKNESS OF THE SHIM. EXAMPLE: 078P 0066218 – MADE FROM 18 GAUGE STEEL

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ROTATING PARTS – LIFTING PROCEDURE:

ALIGNMENT CLEARANCE CLASS 4

SIZE AA 171 .008 TO .013 198 .009 TO .014 231 .010 TO .015 270 .012 TO .017 315 .012 TO .017 366 .012 TO .017 427 .015 TO .020 497 .017 TO .022

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ROTATING PARTS – EXPLODED VIEW:

- 25 -

IMPELLER PILLOW BLOCK:

SIZE C 171, 198 .010 231, 270, 315, 366

.015

427, 497 .020 CL4- T006

26

RUNNER PILLOW BLOCK:

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SPEED CONTROLLER ASSEMBLY:

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STORAGE GUIDELINES: The following storage guidelines are for use with all Classes of Gýrol Fluid Drives. GENERAL INFORMATION

Scope These guidelines contain suggested procedures for protecting Gýrol Fluid Drives during storage. It is intended to serve as a minimum guide only, and will not supplant common logic on behalf of owners for additional safeguards to ensure safe storage where special precautions are warranted.

Related Documents Additional documents such as the appropriate instruction book are to be used prior to start-up of Gýrol Fluid Drives following storage. Definition As used herein, unit not installed or placed in service: Short term storage will be less than six months and long term storage will be greater than six months. Responsibility Responsibility for the integrity of the Gýrol Fluid Drive during storage must be assumed by the owner. Howden will not be responsible for damage to equipment during storage.

SPECIAL NOTE: For long term storage, we recommend the user employ services of a firm specializing in preparation of mechanical equipment for storage and follow recommendations contained herein.

BEFORE STORAGE (Unit not installed or placed in service)

The Fluid Drive should be inspected before being placed in storage to ensure good condition such as absence of moisture and rust. Drive may be inspected by lifting the main housing cover or one of the access covers, depending on the class of Fluid Drive. If paint has peeled from inside of housing, clean affected area and repaint with Rust Ban 297 or equivalent. Follow paint manufacturer’s recommendations for preparing surfaces. If water has collected inside the housing, wipe dry and clean thoroughly with lint-free rag.

Auxiliary equipment such as pressure and temperature gauges must be removed and boxed separately. All openings must be closed weather-tight with pipe fittings or equivalent courses.

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SHORT TERM STORAGE (Unit not installed or placed in service) Inside Storage

Heated Building: It is preferred to have Gýrol Fluid Drives stored in heated buildings. Place Fluid Drive on suitable wood skid to raise it above floor level. Except for insuring all exterior gauges and switches are protected from damage, no further preparations are necessary for short term storage inside heated buildings. Unheated Building: If Gýrol Fluid Drive is to be stored in an unheated building, the following procedure is recommended: 1. Lift drive above floor level by placing on suitable wood skid as above. 2. Apply a protective coating of oil soluble rust preventative (Mobilarma #778

or equivalent) to all accessible and unpainted steel surfaces, both inside and outside Fluid Drive. Inside components are accessible by removing housing cover or one of access covers.

3. Place at least two one-pound bags of desiccant inside tank to absorb moisture (See section On Line Storage).

4. Seal all openings.

Outside Storage The outside storage of Gýrol Fluid Drive is not recommended. If necessary, the following procedure is recommended to preserve the unit. 1. Follow all steps given above for unheated building storage. 2. Both input and output shafts must be covered with rust preventative, such

as Esso Rust Ban 373 or equivalent. 3. After covering shafts with rust preventative, they must be wrapped with

moisture-proof paper or cloth and masking tape. 4. Close all openings with gasketed wooden covers. 5. Cover complete drive with canvas or plastic sheeting. Encapsulate.

LONG TERM STORAGE (Unit not installed or placed in service) Inside Storage

Heated Building Follow same preparation as short term storage inside-heated building. (See previous section)

Unheated Building If Gýrol Fluid Drive is to be stored in unheated building, the following procedure is recommended.

1. Follow all steps given under short term inside storage-unheated building.

2. Coat external shaft extensions with rust preventative and cover with protective paper or cloth covers.

3. Fluid Drive should be examined at least every six months for signs of rusting and/or moisture collecting due to humidity.

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Outside Storage The outside storage of Gýrol Fluid Drive is not recommended. If necessary, the following procedure is to be used:

1. Follow all steps given above for unheated building storage. 2. Coat external shaft extensions and scoop control rod with rust

preventative. Cover shaft and rod with moisture-proof paper. 3. Apply protective coating of oil soluble rust preventative to normally

inaccessible locations by fogging (spraying) into rotors, pillow block, shaft seals and all piping.

4. Close all openings weather-tight with gasketed wooden covers. 5. Cover complete Fluid Drive with canvas or plastic sheeting.

Encapsulate. 6. Place covered Fluid Drive inside wood crate lined with waterproof

paper or plastic lining. Encapsulate. 7.

ON-LINE STORAGE This is for Class 2 Sizes 315 and 366, Classes 4, 5, 6, and 7, installed but not placed in service or unit to be removed from service. Follow the steps below for storage procedure. Note: Class 2 (Sizes 55 through 270) Fluid Drive, drain oil and follow instructions in section on Short Term Storage, steps 2 and 3; and section on On-Line Storage-Associated Equipment, External Piping, Cooler And Oil Pump, step 4. 1. Drain oil from Fluid Drive if unit is being removed from service. 2. Remove Fluid Drive tank cover and make sure unit is dry. If moisture is

present, wipe dry with lint-free rag. If traces of rust appear on stationary or rotating parts, remove rust with solvent, crocus cloth or fine emery paper and oil. Use great care to collect and dispose of all removed particles. Wipe surface clean with lint-free cloth.

3. Spray or brush all unpainted and machined parts with rust inhibiting oil, Gulfcrest TD, Shell Ensis 210 or equivalent.

4. Open all oil-fill holes and drains, breaking connections where necessary to fog internal piping with rust inhibiting oil. Fog the inside of rotors through the eye of scoop tube casing. Remove pipe plugs from bearing pillow blocks directly across from lube lines or disconnect lube lines and fog radial and thrust bearing areas. Before replacing pipe plugs or reconnecting lube lines, pour a can of STP Oil Treatment in each bearing.

5. Suspend bags of desiccant, (Dessicite 25 by Filtrol Corporation, Los Angeles, California or equivalent) in air space of Fluid Drive housing, in accordance with manufacturer recommendations. Suspend or support bags in free air sections of Fluid Drive housing, spaced equally as possible, and making certain bags do not contact the metal surfaces. The time interval between bag replacements will depend upon humidity level of area.

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6. Inspect covers and seals on flanged connections, repair and reseal as necessary. Replace tank cover and seal all openings water and air tight after completing operations under Section 3.0.

7. Make sure shaft extension, shaft keys, and flexible half coupling have an unbroken protective coating. Remove all rust with fine crocus cloth and wipe clean by swabbing with Tectyl 506 (Valvoline Oil Company) or equivalent.

8. Provide air tight seal on both ends where shafts emerge from housing. 9. To accomplish this, use vapor-proof material (MIL-B-131, Class 1,

plastic and non-woven) sealed with masking tape. Repeat procedure where scoop control rod extends through the side of tank. Wrap and seal off breather on top of tank cover.

ON-LINE STORAGE – ASSOCIATED EQUIPMENT External Piping, Cooler And Oil Pump

1. Disconnect external piping from the Fluid Drive tank and install blank-off plates (14 to 16 gallon) with gaskets on pipe flange connections of Fluid Drive tank and external piping. Install vent stand pipes 1/2” diameter or larger in external piping system and a fill stand-pipe in highest section of external piping.

2. With upper portion of circuit fill manifold removed, pour recommended oil used during normal operation of Fluid Drive into circuit fill pipe until oil filter piping and internal lube manifold are full. When filling external piping system, oil pump must be rotated by hand in order to assure filling pumps and all discharge piping.

3. When system is full, cap vent and fill stand-pipes and replace upper portion of circuit fill oil manifold piping inside tank.

4. Inspect for any oil leakage and remedy if necessary. 5. Remove the oil cooler water box drain plugs at each end of the cooler

to be sure all water is drained from the water side of the cooler and then replace the plugs. (If necessary, use compressed air to blow out tubes.)

Gauge Panel, Instrumentation, Controller, etc. 1. Protect and cover gauge panel with polyethylene. 2. Check thermocouple junction box and make sure it is properly sealed. 3. Controller, if furnished by Howden, must be protected and covered with

polyethylene. 4. Any applicable instructions given by Manufacturer of oil cooler or

external oil pump set should also be observed. ON-LINE STORAGE - STORAGE OPERATIONS AND INSPECTION

Monthly, rotate Fluid Drive rotors 10 to 15 complete revolutions to wet journal bearings. Monthly, check condition of external surfaces. If signs of rust appear on external surfaces of equipment, restore to good condition.

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Every three months, rotate external oil pump and motor several revolutions by hand so grease lubricated bearings are wetted and bearing ball position changed.

ON-LINE STORAGE - CONTINUED STORAGE BEYOND ONE YEAR Repeat storage procedures starting with On-Line Storage section and in addition remove one of Fluid Drive shaft bearing caps and check condition inside bearing. Clean up and protect as required. Inspection of equipment should indicate how often a complete treatment is needed.

PROCEDURE AFTER STORAGE

Prior to placing Fluid Drive into service after storage, the following procedure is recommended. 1. Remove housing cover or access door and examine interior for rust or

moisture. Clean and repaint as required. 2. Remove desiccant bags. 3. Install Fluid Drive on suitable sub-base following instructions in the

Manual; or, if returning from On-Line Storage, re-check alignment to driving and driven machine.

4. If unit has never been in service, remove shipping strap inside housing. 5. Install and adjust scoop tube control. Follow instructions given in

Manual. 6. Install various pressure and temperature gauges. 7. Oil soluble rust preventative does not require removal prior to service. 8. Hard surface protection, such as Esso Rust Ban 373, should be

removed prior to service by using a suitable solvent. 9. Prior to start-up, clean unit thoroughly according to Instruction Manual. 10. Units having an externally mounted oil supply require oil carrying

pipes, vessels, valves, coolers, etc. are flushed prior to placing unit into operation.

11. Follow Flushing Procedure in Installation Manual. 12. Fill drive with new, clean oil. Follow Instruction Manual for correct oil

quantity and procedure for placing Fluid Drive into service. START-UP

Before starting Gýrol Fluid Drive, refer to Operating Instructions.

SECTION 2 Drawings

SECTION 2 - Drawings

SECTION 3 Auxiliary Components

PRESSURE GAUGEINSTALLATION, OPERATION ANDMAINTENANCE

PART NO. 250-1353H

a Halliburton company

ii

iii

CONTENTS

1.0 Selection and Application1.1 Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.2 Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.3 Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.4 Oxidizing media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.5 Pulsation/Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.6 Gauge fills . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.7 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

2.0 Temperature2.1 Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22.2 Accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22.3 Steam service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22.4 Hot lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22.5 Cold service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22.6 Diaphragm seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22.7 Autoclaving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

3.0 Installation 3.1 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33.2 Gauge reuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33.3 Tightening of gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33.4 Process isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33.5 Surface mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33.6 Flush mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

4.0 Operation4.1 Frequency of inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34.2 In-service inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34.3 When to check accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34.4 When to recalibrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34.5 Other considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34.6 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

5.0 Gauge Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

6.0 Accuracy: Procedures/Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-56.1 Calibration - Rotary movement gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76.2 Calibration - 1009 Duralife® Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Page

iv

CONTENTS

7.0 Diaphragm Seals7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127.4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127.5 Failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

8.0 Dampening Devices8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138.2 Throttle Screws & Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138.3 Ashcroft Gauge Saver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138.4 Ashcroft Pulsation Dampener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138.5 Ashcroft Pressure Snubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138.6 Campbell Micro-Bean® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138.7 Ashcroft Needle Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138.8 Chemiquip® Pressure Limiting Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

9.0 Resources9.1 Training Videos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149.2 Pressure Instrument Testing Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149.3 Tools & Tool Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149.4 Sales Bulletins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Page

Cover photo courtesy of Johnson/Yokogawa Co.

Campbell Micro-Bean® is a registered trademark of J.A. Campbell Co.

Chemiquip® is a registered trademark of Chemiquip Products Co. Inc.

1.0 SELECTION & APPLICATION

Users should become familiar with ASMEB40.1 (Gauges – Pressure Indicating DialType – Elastic Element) before specifyingpressure measuring instruments. That docu-ment – containing valuable informationregarding gauge construction, accuracy, safe-ty, selection and testing – may be orderedfrom The American Society of MechanicalEngineers, 345 East 47th Street, New York,N.Y. 10017.

WARNING: To prevent misapplication, pres-sure gauges should be selected consideringmedia and ambient operating conditions.Improper application can be detrimental tothe gauge, causing failure and possible per-sonal injury, property damage or death. Theinformation contained in this manual isoffered as a guide in making the proper selec-tion of a pressure gauge. Additional informa-tion is available from Dresser InstrumentDivision.

The following is a highlight of some of themore important considerations:

1.1 Range – The range of the instrumentshould be approximately twice the maximumoperating pressure. Too low a range mayresult in (a) low fatigue life of the elastic ele-ment due to high operating stress and (b) sus-ceptibility to overpressure set due to pressuretransients that exceed the normal operatingpressure. Too high a range may yield insuffi-cient resolution for the application.

1.2 Temperature – Refer to page 2 of thismanual for important information concerningtemperature related limitations of pressuregauges, both dry and liquid filled.

1.3 Media – The material of the process sens-ing element must be compatible with theprocess media from a corrosion point of view.Consult the Corrosion Guide available on thewebsite: www.dresserinstruments.com orDresser Instrument Division. Use of adiaphragm seal with the gauge is recom-mended for process media that (a) are corro-

sive to the process sensing element; (b) con-tain heavy particulates (slurries) or (c) arevery viscous including those that harden atroom temperature. Additionally, diaphragmseals with flexible line assemblies should beconsidered for applications involving hot lines(see page 2) or significant levels of vibrationand/or pulsation.

1.4 Oxidizing media – It is extremely impor-tant that when specifying gauges for use onoxidizing media the appropriate gauge clean-liness level per ASME B40.1 be included inthe gauge specification. Gauges containingsignificant amounts of hydrocarbon contami-nation inside the pressure system will oftenrupture explosively in such service.

1.5 Pulsation/Vibration – Severe serviceapplications are characterized by the pres-ence of significant levels of pressure pulsationand/or vibration. Gauges should be protectedfrom severe pressure pulsation by the inclu-sion of a dampener such as a throttleplug/screw or porous metal snubber. If thepulsation is extreme, a liquid filled gauge,with dampener should be used. A liquid filledgauge will also last significantly longer than acomparable dry gauge when vibration is pre-sent. If the vibration levels are extreme theonly solution may be to remotely mount thegauge away from the source of vibration. Inthat case flexible tubing may be used to con-nect the gauge to the pressure source.

1.6 Gauge fills. – Once it has been determinedthat a liquid filled gauge is in order, the nextstep is selecting the type of fill. Glycerin sat-isfies most applications. While being the leastexpensive fill, its usable temperature range is0/250°F. Silicone filled gauges have a broad-er service range: –40/250°F. Oxidizing mediarequire the use of a compatible gauge fill suchas Halocarbon, with a service range of–50/250°F .

1.7 Mounting – Users should predeterminehow the gauge will be mounted in service:stem (pipe), wall (surface) or panel (flush).Ashcroft wall or panel mounting kits shouldbe ordered with the gauge.

1

2.0 TEMPERATURE

2.1 Ratings – To ensure long life and accuratereadings, pressure gauges should not beexposed to process or ambient temperaturesover 150°F. This is especially true of gaugeswith liquid filled cases due to thermal expan-sion of the case fill fluid. Long term exposureto temperatures in excess of 150°F may causediscoloration of dials and fill fluids, as well ashardening of elastomeric case seals and possi-ble fill leakage. Soft soldered, silver brazedand welded pressure joints are rated at 250°Fmaximum, 450°F maximum and 750°F maxi-mum respectively. Plastic gauge cases, includ-ing phenolic, should not be exposed to tem-peratures in excess of 250°F. Maximum rec-ommended service temperatures for gaugewindows are as follows: 350°F for plain glass;300°F for polysulfone; 270°F for polycarbon-ate; 200°F for laminated safety glass; and180°F for acrylic.

2.2 Accuracy – Heat and cold affect accuracyof indication. A general rule of thumb for drygauges is 0.5% of full scale change for every40°F change from 75°F. Double that al-lowance for gauges with hermetically sealedor liquid filled cases, except for Duragauge®

gauges where no extra allowance is requireddue to the elastomeric, compensating back.Above 250°F there may exist very significanterrors in indication.

2.3 Steam service – In order to prevent livesteam from entering the bourdon tube, asiphon filled with water should be installedbetween the gauge and the process line.Siphons can be supplied with ratings up to4,000 psi at 1,000°F. If freezing of the conden-sate in the loop of the siphon is a possibility, adiaphragm seal should be used to isolate thegauge from the process steam. Siphons shouldalso be used whenever condensing, hot vapors(not just steam) are present.

2.4 Hot lines – When a gauge is installed on aprocess line containing hot liquid or gas, onesolution is to simply include an extra foot(200°F process) to 4 feet (600°F process) of

1/2˝ piping (or smaller diameter flexible tub-ing) between the hot line and the gauge. Theslow rate of heat transfer through the addedpipe wall and dead-ended process fluid willgenerally protect the gauge from damage.

2.5 Cold Service – The minimum recom-mended operating temperature for all gaugesis –50°F. A hermetically sealed gauge case isrecommended to minimize condensate freez-ing on the movement, thus hindering itsaction. Gauges filled with silicone oil will pro-vide maximum resistance to the effects ofoperating in freezing conditions. While glyc-erin filled gauges can be safely stored at tem-peratures down to –50°F , their operation isimpeded at temperatures below +20°F due tothe marked increase in the viscosity of theglycerin.

2.6 Diaphragm seals – Diaphragm seals(isolators) with filled, flexible line assembliesare another good solution to the problem ofhot liquid and gas lines. Due to the smalldiameter of the flexible line (capillary) a fivefoot line length will usually assure that thetemperature of the gauge connection does notexceed 150°F. Even one foot of capillary oftenwill prevent the high temperature of the sealfrom reaching the gauge. This solution is alsosuperior to a siphon on steam service wherethe water filled siphon might freeze. Refer tosales bulletin DS-1 for a listing of service tem-perature ranges by type of fill.

2.7 Autoclaving – Sanitary gauges withclamp type connections are frequently steamsterilized in an autoclave. Gauges equippedwith polysulfone windows will withstandmore autoclave cycles than those equippedwith polycarbonate windows. Gaugesequipped with plain glass or laminated safetyglass should not be autoclaved. Gaugecases should be vented to atmosphere (remov-ing the rubber fill/safety plug if necessary)before autoclaving to prevent the plasticwindow from cracking or excessively distort-ing. If the gauge is liquid filled, the fill shouldalso be drained from the case before autoclav-ing.

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3.0 INSTALLATION

3.1 Location – Whenever possible, gaugesshould be located to minimize the effects ofvibration, extreme ambient temperatures andmoisture. Dry locations away from very highthermal sources (ovens, boilers etc.) are pre-ferred. If the mechanical vibration level isextreme, the gauge should be remotely locat-ed (usually on a wall) and connected to thepressure source via flexible tubing.

3.2 Gauge reuse – ASME B40.1 recommendsthat gauges not be moved indiscriminatelyfrom one application to another. Whereas thecumulative number of pressure cycles on anin-service or previously used gauge is gener-ally unknown, it is generally safer to install anew gauge whenever and wherever possible.This will also minimize the possibility of areaction with previous media.

3.3 Tightening of gauge – Torque shouldnever be applied to the gauge case. Instead,an open end or adjustable wrench shouldalways be used on the wrench flats of thegauge socket to tighten the gauge into the fit-ting or pipe. NPT threads require the use of asuitable thread sealant, such as pipe dope orteflon tape, and must be tightened verysecurely to ensure a leak tight seal.

CAUTION: Torque applied to a diaphragmseal or its attached gauge, that tends toloosen one relative to the other, can cause lossof fill and subsequent inaccurate readings.Always apply torque only to the wrench flatson the lower seal housing when installingfilled, diaphragm seal assemblies or removingsame from process lines.

3.4 Process isolation – A shut-off valveshould be installed between the gauge andthe process in order to be able to isolate thegauge for inspection or replacement withoutshutting down the process.

3.5 Surface mounting – Also known as wallmounting. Gauges should be kept free of pip-ing strains. The gauge case mounting feet, ifapplicable, will ensure clearance between the

pressure relieving back and the mountingsurface.

3.6 Flush mounting – Also known as panelmounting. The applicable panel mountingcutout dimensions can be found in Ashcroftsales bulletins – see item 9.4 RESOURCESon page 14 of this manual. These dimensionsare also on Ashcroft® gauge general dimensiondrawings which can be obtained from theCustomer Service department in Stratford,Connecticut.

4.0 OPERATION

4.1 Frequency of inspection – This is quitesubjective and depends upon the severity ofthe service and how critical the accuracy ofthe indicated pressure is. For example, amonthly inspection frequency may be in orderfor critical, severe service applications.Annual in-spections, or even less frequentschedules, are often employed in non-criticalapplications.

4.2 In-service inspection – If the accuracy ofthe gauge cannot be checked in place, the usercan at least look for (a) erratic or randompointer motion; (b) readings that are suspect– especially indications of pressure when theuser believes the true pressure is 0 psig.

4.3 When to check accuracy – Obviously anysuspicious behavior of the gauge pointer war-rants a full accuracy check be performed.Even if the gauge is not showing any symp-toms of abnormal performance, the user maywant to establish a frequency of bench typeinspection.

4.4 When to recalibrate – This depends on thecriticality of the application. If the accuracy ofa 3-2-3% commercial type gauge is only 0.5%beyond specification, the user must decidewhether it’s worth the time and expense tobring the gauge back into specification.Conversely if the accuracy of a 0.25% testgauge is found to be 0.1% out of specificationthen obviously the gauge should be recalibrat-ed.

3

4.5 Other considerations – These include (a)bent or unattached pointers due to extremepressure pulsation; (b) broken windows whichshould be replaced to keep dirt out of theinternals; (c) leakage of gauge fill; (d) casedamage – dents and/or cracks; (e) any signs ofservice media leakage through the gaugeincluding its connection; (f) discoloration ofgauge fill that impedes readability.

4.6 Spare parts – As a general rule it is rec-ommended that the user maintain in hisparts inventory one complete Ashcroft instru-ment for every ten (or fraction thereof) of thatinstrument type in service.

5.0 GAUGE REPLACEMENT

It is recommended that the user stock onecomplete Ashcroft instrument for every ten(or fraction thereof) of that instrument type inservice. With regard to gauges having a ser-vice history, consideration should be given todiscarding rather than repairing them.Gauges in this category include the following:

a. Gauges that exhibit a span shift greaterthan 10%. It is possible the bourdon tubehas suffered thinning of its walls by corro-sion.

b. Gauges that exhibit a zero shift greaterthan 25%. It is likely the bourdon tube hasseen significant overpressure leavingresidual stresses that may be detrimentalto the application.

c. Gauges which have accumulated over1,000,000 pressure cycles with significantpointer excursion.

d. Gauges showing any signs of corrosionand/or leakage of the pressure system.

e. Gauges which have been exposed to hightemperature or simply exhibit signs ofhaving been exposed to high temperature– specifically 250°F or greater for soft sol-dered systems; 450°F or greater for brazedsystems; and 750°F or greater for weldedsystems.

f. Gauges showing significant friction errorand/or wear of the movement and linkage(assuming the movement cannot bereplaced).

g. Gauges having damaged sockets, especial-ly damaged threads.

h. Liquid filled gauges showing loss of casefill.

NOTE: ASME B40.1 does not recommendmoving gauges from one application to anoth-er. This policy is prudent in that it encouragesthe user to procure a new gauge, properly tai-lored by specification, to each application thatarises.

6.0 ACCURACY:PROCEDURES/DEFINITIONS

Accuracy inspection – Readings at approxi-mately five points equally spaced over thedial should be taken, both upscale and down-scale, before and after lightly rapping thegauge to remove friction. A pressure standardwith accuracy at least 4 times greater thanthe accuracy of the gauge being tested is rec-ommended.

Equipment – A finely regulated pressure sup-ply will be required. It is critical that the pip-ing system associated with the test setup beleaktight. The gauge under test should bepositioned as it will be in service to eliminatepositional errors due to gravity.

Method – Two checking techniques exist –direct and reverse reading. ASME B40.1 rec-ommends the direct approach whereinknown pressures are applied and readingsare taken from the gauge under test. Whenthe gauge under test has a relatively coarselygraduated dial, it is tempting to use thereverse method wherein the applied pressureis adjusted to precisely align its pointer witha dial graduation and then readings are takenfrom the pressure standard. The reversereading technique is often misleading andshould not be used.

4

Calibration chart – After recording all of thereadings it is necessary to calculate the errorsassociated with each test point using the fol-lowing formula: ERROR in percent = 100times (TRUE VALUE minus READING) ÷RANGE. Plotting the individual errors(Figure 1 on page 6) makes it possible to visu-alize the total gauge characteristic. The plotshould contain all four curves: upscale –before rap; upscale – after rap; downscale –before rap; downscale – after rap. Rap meanslightly tapping the gauge before reading toremove friction as described in ASME B40.1.

Referring to Figure 1 on page 6, several class-es of error may be seen:

Zero – An error which is approximately equalover the entire scale. This error can be mani-fested when either the gauge is dropped oroverpressured and the bourdon tube takes apermanent set. This error may often be cor-rected by simply repositioning the pointer.Except for test gauges, it is recommendedthat the pointer be set at midscale pressure to“split” the errors.

Span – A span error exists when the error atfull scale pressure is different from the errorat zero pressure. This error is often propor-tional to the applied pressure. Most Ashcroftgauges are equipped with an internal, adjust-ing mechanism with which the user can cor-rect any span errors which have developedin service.

Linearity – A gauge that has been properlyspanned can still be out of specification atintermediate points if the response of thegauge as seen in Figure 1 on page 6 is not lin-ear. The Ashcroft Duragauge® is equippedwith a rotary movement feature which per-mits the user to minimize this class of error.Other Ashcroft gauge designs (e.g., 1009Duralife®) require that the dial be moved leftor right prior to tightening the dial screws.

Hysteresis – Some bourdon tubes have amaterial property known as hysteresis. Thismaterial characteristic results in differencesbetween the upscale and downscale curves.This class of error can not be eliminatedby adjusting the gauge movement or dial position.

Friction – This error is defined as the differ-ence in readings before and after lightly rap-ping the gauge case. If excessive, the move-ment should be replaced (if replaceable bydesign). One possible cause of excessive fric-tion is improper adjustment of the hairspring.The hairspring should be level and the coilsshould not touch or distort at any pointbetween zero and full scale. The hairspringtorque should also be at a near optimum level– adequate without being excessive.

(Continued on page 7)

5

TYPICAL CALIBRATION CHARTINDICATED VALUE (PSI)

True Value – Increasing – Increasing – Decreasing – Decreasing –PSI Without RAP With RAP Without RAP With RAP

0 –.4 0 –.4 040 +.8 +1.0 +1.4 +1.180 +.4 +.5 +1.2 +1.0

120 –.4 –1.0 +.8 +.6160 –.8 –.5 +.6 +.4200 +.4 +.8 +.4 +.4

ERROR (% OF FULL SCALE)

True Value – Increasing – Increasing – Decreasing – Decreasing –% of Range Without RAP With RAP Without RAP With RAP

0 –.20 0 –.20 020 +.40 +.50 +.70 +.5540 +.20 +.25 +.60 +.5060 –.20 –.05 +.40 +.3080 –.40 –.25 +.30 +.20

100 +.20 +.40 +.20 +.20

6

1.0

0.5

0.0

–0.5

–1.0

0 20 40 60 80 100% of Range

upscale – without rap

upscale – with rap

downscale – without rap

downscale – with rap

Err

or

(% o

f F

ull

Sca

le)

Fig. 1

6.1 Calibration – Rotary Movement Gauges– Inspect gauge for accuracy. Many timesgauges are simply “off zero” and a simplepointer adjustment using the micrometerpointer is adequate. If inspection shows thegauge warrants recalibration to correct spanand/or linearity errors, proceed as follows:

a. Remove ring, window and, if solid frontcase, the rear closure assembly.

b. Pressurize the gauge once to full scale andback to zero.

c. Refer to Figure 2 on page 8 for a view of atypical Ashcroft system assembly withcomponent parts identified.

d. For solid front gauges, adjust the microm-eter pointer so that it rests at the true zeroposition. For open front gauges the pointerand dial must also be disassembled andthe pointer should then be lightly pressedonto the pinion at the 9:00 o’clock position.

e. Apply full scale pressure and note themagnitude of the span error. With openfront gauges, ideal span (270 degrees) willexist when at full scale pressure the point-er rests exactly at the 6:00 o’clock position.

f. If the span has shifted significantly (spanerror greater than 10%), the gauge shouldbe replaced because there may be somepartial corrosion inside the bourdon tubewhich could lead to ultimate failure. If thespan error exceeds 0.25%, loosen the lowerlink screw and move the lower end of thelink toward the movement to increasespan or away to decrease span. An adjust-ment of 0.004 inch will change the span byapproximately 1%. This is a repetitive pro-cedure which often requires more than oneadjustment of the link position and thesubsequent rechecking of the errors at zeroand full scale pressure.

g. Apply midscale pressure and note error inreading. Even though the gauge is accu-rate at zero and full scale, it may be inac-curate at the midpoint. This is called lin-earity error and is minimized by rotatingthe movement. If the error is positive, the

movement should be rotated counter clock-wise. Rotating the movement one degreewill change this error by approximately0.25%. Rotating the movement oftenaffects span and it should be subsequentlyrechecked and readjusted if necessaryaccording to step 6.1e and 6.1f.

h. While recalibrating the gauge, the frictionerror – difference in readings taken withand without rap – should be noted. Thiserror should not exceed the basic accuracyof the gauge. If the friction error is exces-sive, the movement should be replaced.One possible cause of excessive friction isimproper adjustment of the hairspring.The hairspring torque,or tension, must beadequate without being excessive. Thehairspring should also be level, unwindevenly (no turns rubbing) and it shouldnever tangle.

NOTES:1 For operation of test gauge external zero

reset, refer to Figure 3 on page 8.2 For test gauge calibration procedure,

refer to Figure 4 on page 9.

6.2 Calibration – 1009 Duralife® Gauge –Inspect gauge for accuracy. Many timesgauges are simply “off zero” and a simplepointer adjustment using the adjustablepointer is adequate. If the inspection showsthat the gauge warrants recalibration to cor-rect span and/or linearity errors, proceed asfollows:

Remove ring, window, gasket and pointerusing Ashcroft tool kits 1205T and 1206T.

Positive Pressure Ranges –

a. Remove dial and lightly press pointer ontopinion at 9:00 o’clock position.

b. Apply full scale pressure and rotate spanblock as shown in Figure 5a on page 11until pointer rests at 6:00 o’clock position.

c. Fully exhaust pressure and check thatpointer still is at 9:00 o’clock position. Ifnot repeat steps 1 and 2 until span iscorrect.

7(Continued on page 10)

8

BOURDON TUBESEGMENT

TIP

LINK

BACKPLATE

SOCKET

ROTARY MOVEMENT

PINION

HAIRSPRING

Fig. 2

TYPE 1082 EXTERNAL ZERO ADJUST FEATURE*

ARING

INSTRUCTIONS FOR USE:LOOSEN RING LOCKING SCREW “A’’OBTAIN REQUIRED ADJUSTMENT BY ROTATINGKNOB “B’’ CLOCKWISE OR COUNTER-CLOCKWISE.TIGHTEN SCREW “A’’ DOWN ON KNOB “B.’’

*Applicable only for test gauge with hinged ring design.

B

ASHCROFT SYSTEM ASSEMBLY

Fig. 3

9

TYPE 1082 TEST GAUGE CALIBRATION PROCEDUREFig. 4

d. Remove pointer and reassemble dial anddial screws (finger tight).

e. Lightly press pointer onto pinion.

f. Check accuracy at full scale. If errorexceeds 1% return to step 1, otherwise pro-ceed.

g. Check accuracy at midscale. If errorexceeds 1% slide dial left or right to com-pensate.

h. Continue at * below.

Vacuum range –

a. Using a pencil, refer to dial and mark the0 and 25 inch of Hg positions on the caseflange.

b. Remove the dial.

c. Apply 25 inches of Hg vacuum.

d. Lightly press pointer onto pinion carefullyaligning it with the 25 inch of Hg vacuummark on case flange.

e. Release vacuum fully.

f. Note agreement of pointer to zero mark oncase flange.

g. If span is high or low, turn span block asshown in Figure 5b on page 11.

h. Repeat steps 4 through 8 until span iscorrect.

i. Remove the pointer.

j. With 25 inches of Hg vacuum applied,reassemble dial, dial screws (finger tight)and pointer.

k. Apply 15 inches of Hg vacuum and noteaccuracy of indication. If required, slidedial left or right to reduce error to 1% maximum.

l. Continue at * below.

* Now complete calibration of the gauge asfollows:

a. Firmly tighten dial screws.

b. Firmly tap pointer onto pinion, using brassback-up tool from Ashcroft kit 1205T ifgauge has rear blow-out plug. If gauge hastop fill hole no back-up is required.

c. Recheck accuracy at zero, midscale andfull scale points (Figures 5a & 5b onpage 11).

d. Reassemble window, gasket and ring.

10

11

Start at 9:00 o’clock

Decrease Increase

End at 6:00 o’clock

Decrease Increase

Pencil marks on case flange

Span Block

25

07/64 Open End Wrench

1009 DURALIFE CALIBRATION

PRESSURE VACUUM

0

25

15

Mid-scale mark

Full scale mark

Dial screwsZero box

Fig. 5a Fig. 5bFig. 5a Fig. 5b

1009 DURALIFE® PRESSURE GAUGE CALIBRATION

7.0 DIAPHRAGM SEALS

7.1 General – A diaphragm seal (isolator) is adevice which is attached to the inlet connec-tion of a pressure instrument to isolate itsmeasuring element from the process media.The space between the diaphragm and theinstrument’s pressure sensing element issolidly filled with a suitable liquid.Displacement of the liquid fill in the pressureelement, through movement of thediaphragm, transmits process pressurechanges directly to a gauge, switch or anyother pressure instrument. When diaphragmseals are used with pressure gauges, an addi-tional 0.5% tolerance must be added to thegauge accuracy because of the diaphragmspring rate.

Used in a variety of process applicationswhere corrosives, slurries or viscous fluidsmay be encountered, the diaphragm sealaffords protection to the instrument where:

• The process fluid being measured wouldnormally clog the pressure element.

• Pressure element materials capable ofwithstanding corrosive effects of certainfluids are not available.

• The process fluid might freeze due tochanges in ambient temperature and dam-age the element.

7.2 Installation – Refer to sales bulletin DS-1for information regarding (a) seal configura-tions; (b) filling fluids; (c) temperature rangeof filling fluids; (d) diaphragm material pres-sure and temperature limits; (e) bottom hous-ing material pressure and temperature lim-its; (f) pressure rating of seal assembly; (g)accuracy/temperature errors of seal assembly;(h) diaphragm seal displacement. The volu-metric displacement of the diaphragm mustat least equal the volumetric displacement ofthe measuring element in the pressureinstrument to which the seal is to beattached.

It is imperative that the pressure instru-

ment/diaphragm seal assembly be properlyfilled prior to being placed in service. Ashcroftdiaphragm seal assemblies should only befilled by a seal assembler certified by DresserIndustries. Refer to section 3.3 for a caution-ary note about not applying torque on eitherthe instrument or seal relative to the other.

7.3 Operation – All Ashcroft diaphragm seals,with the exception of Type 310 mini-seals, arecontinuous duty. Should the pressure instru-ment fail, or be removed accidentally or delib-erately, the diaphragm will seat against amatching surface preventing damage to thediaphragm or leakage of the process fluid.

7.4 Maintenance – Clamp type diaphragmseals – Types 100, 200 and 300 – allow forreplacement of the diaphragm or diaphragmcapsule, if that ever becomes necessary. TheType 200 top housing must also be replacedwith the diaphragm. With all three types theclamping arrangement allows field disassem-bly to permit cleaning of the seal interior.

7.5 Failures – Diaphragm failures are gener-ally caused by either corrosion, high tempera-tures or fill leakage. Process media build-upon the process side of the diaphragm can alsorequire seal cleaning or replacement. ConsultCustomer Service, Stratford CT for advice onseal failures and/or replacement. Refer also toProduct Information page ASH/PI-14C con-taining drawing 96A121 Corrosion DataGuide.

WARNING: All seal components should beselected considering process and ambientoperating conditions to prevent misapplica-tion. Improper application could result in fail-ure, possible personal injury, propertydamage or death.

8.0 DAMPENING DEVICES

8.1 General – Some type of dampening deviceshould be used whenever the pressure gaugemay be exposed to repetitive pressure fluctu-ations that are fairly rapid, high in magni-tude and especially when transitory pressurespikes exceeding the gauge range are present

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(as with starting and stopping action of valvesand pumps). A restricted orifice of some kindis employed through which pressure fluctua-tions must pass before they reach the bourdontube. The dampener reduces the magnitude ofthe pressure pulse thus extending the life ofthe bourdon tube and movement. This reduc-tion of the pressure pulsation as “seen” by thepressure gauge is generally evidenced by areduction in the pointer travel. If the orifice isvery small the pointer may indicate the aver-age service pressure, with little or no indica-tion of the time varying component of theprocess pressure.

Commonly encountered media (e.g. – waterand hydraulic oil) often carry impuritieswhich can plug the orifice over time thus ren-dering the gauge inoperative until the damp-ener is cleaned or replaced.

Highly viscous media and media that tend toperiodically harden (e.g., asphalt) require adiaphragm seal be fitted to the gauge. Theseal contains an internal orifice which damp-ens the pressure fluctuation within the fillfluid.

8.2 Throttle Screws & Plugs – These acces-sories provide dampening for the least cost.They have the advantage of fitting complete-ly within the gauge socket and come in threetypes: (a) a screwed-in type which permitseasy removal for cleaning or replacement; (b)a pressed in, non-threaded design and (c) apressed in, threaded design which provides ahighly restrictive, helical flow path. Not allstyles are available on all gauge types.

8.3 Ashcroft Gauge Saver – Type 1073Ashcroft Gauge Saver features an elastomer-ic bulb that fully isolates the process mediafrom the bourdon tube. In addition to provid-ing dampening of pressure pulses, the bour-don tube is protected from plugging and cor-rosion. The space between the bulb and bour-don tube is completely filled with glycerin.Felt plugs located between the bulb and bour-don tube are first compressed some amount torestrict the flow of glycerin through an orificeand thus provide a degree of dampening. The

greater the compression of the felts thegreater the degree of dampening.

8.4 Ashcroft Pulsation Dampener – Type1106 Ashcroft Pulsation Dampener is a mov-ing pin type in which the restricted orifice isthe clearance between the pin and any one offive preselected hole diameters. Unlike a sim-ple throttle screw/plug, this device has a self-cleaning action in that the pin moves up anddown under the influence of pressure fluc-tuations.

8.5 Ashcroft Pressure Snubber – The heartof the Type 1112 pressure snubber is a thickporous metal filter disc. The disc is availablein four standard porosity grades.

8.6 Campbell Micro-Bean® – Type 1110 Micro-Bean is a precision, stainless steel, needlevalve instantly adjustable to changing condi-tions of flow and viscosity. A very slight taperon the valve stem fits into tapered hole in thebody. The degree of dampening is easilyadjusted by turning the valve handle. A filteris built into the Micro-Bean to help preventplugging.

8.7 Ashcroft Needle Valves – Type 7001 thru7004 steel needle valves provide varyingdegrees of dampening similar to the CampbellMicro-Bean but with a less precise and lesscostly adjustability. Like the Micro-Beanthese devices, in the event of plugging, caneasily be opened to allow the pressure fluid toclear away the obstruction.

8.8 Chemiquip® Pressure Limiting Valves –Model PLV-255, PLV-2550, PLV-5460, PLV-5500 and PLV-6430, available with and with-out built-in snubbers, automatically “shut off”at adjustable preset values of pressure to pro-tect the gauge from damage to overpressure.They are especially useful on hydraulic sys-tems wherein hydraulic transients (spikes)are common.

13

9.0 RESOURCES9.1 Training Videos

9.1.1 Test gauge calibration 9.1.2 1009 Duralife® calibration 9.1.3 Duragauge® calibration 9.1.4 Diaphragm seal filling

9.2 Pressure Instrument Testing Equipment9.2.1 Type 1305D Deadweight Tester9.2.2 Type 1327D Pressure Gauge Comparator9.2.3 Type 1327CM “Precision” Gauge Comparator

9.3 Tools & Tool Kits9.3.1 Type 2505 universal carrying case for 1082 test gauge9.3.2 Type 266A132-01 span wrench for 1082 test gauge9.3.3 Type 1280 conversion kit for 41⁄2˝ lower connect 1279/1379 9.3.4 Type 1283 conversion kit for 41⁄2˝ back connect 1279/13799.3.5 Type 1284 conversion kit for 6˝ lower & back connect9.3.6 Type 1281 socket O-Ring kit for 1279/1379 lower connect9.3.7 Type 1285 41⁄2˝ ring wrench for 1279/1379 lower & back connect9.3.8 Type 1286 6˝ ring wrench for 1379 lower & back connect9.3.9 Type 1287 cone tool for installing diaphragm & spring on 1279/1379 back connect9.3.10 Type 1105T calibration tool kit (all gauges except 1009 Duralife®)9.3.11 Type 3220 pointer puller (all gauges except 1009 Duralife®)9.3.12 Type. 3530 pinion back-up tool for 1009 Duralife®

9.3.13 Type 1230 throttle plug insertion (1⁄4 NPT) for 1009 Duralife®

9.3.14 Type 1231 throttle plug insertion (1⁄2 NPT) for 1009 Duralife® (body only)9.3.15 Type 1205T calibration hand tools for 1009 Duralife®

9.3.16 Type 1206T ring removal & assembly tools for 1009 Duralife®

9.4 Sales Bulletins9.4.1 Pressure Instrument Testing Equipment – Bulletin TE-19.4.2 Type 1327CM Portable Precision Gauge Comparator – Bulletin TE-29.4.3 Test Gauges – Bulletin TG-29.4.4 Duragauge® Pressure Gauges – Bulletin DU-19.4.5 General Service Gauges – Bulletin IG-19.4.6 Type 1009 Duralife® Industrial Gauges – Bulletin SS-19.4.7 Type 1008 Metric Case Gauges – Bulletin SS-19.4.8 Duralife® Metric Process Gauges – Bulletin SS-19.4.9 Type 1032 Sanitary Pressure Gauges – Bulletin SG-29.4.10 Special Service Gauges – Bulletin IG-19.4.11 Diaphragm Seals – Bulletin DS-1

14

All specifications are subject to change without notice. All sales subject to standard terms and conditions. © Instrument Division, Dresser Equipment Group, Inc. 8/95 5M DPS 2P6/2000

Instrument Division Sales and Customer Service Locations

PART NO. 250-1353H

a Halliburton company

Visit us on the web at:www.dresserinstruments.com

JapanDresser Japan Inc.Room 318, Shin Tokyo Building3-1 Marunouchi 3-Chome,Chiyoda-ku, Tokyo, JapanTel: 813-3201-1501/1506Fax: 813-3213-6567/6673

KoreaDresser International S.A.Korea Office#2015 Kuk Dong Bldg.60-1, 3-KA, Choongmu-Ro, Chungku, Seoul, Korea 100-705Tel: 82-2-2274-079-2/3Fax: 82-2-2274-0794

MexicoDresser Instruments S.A. de, C.V.Henry Ford No. 114, Esq. Foulton, FraccIndustrial San Nicolas54030 Tlalneplantla edo de Mexico 54030Tel: 525-310-7217Fax: 525-310-2608

Saudi ArabiaDresser Al Rushaid(DARVICO)P.O. Box 10145Jubail Industrial CitySaudi Arabia 31961Tel: 966-3-341-0278Fax: 966-3-341-7624

SingaporeDresser Singapore Pte Ltd.Instrument OperationsBlock 1004 Toa Payoh North #07-15/17Singapore 318995Tel: 65-252-6602Fax: 65-252-6603

United KingdomDresser Europe GmbHEast Gillibrands,Skelmersdale,Lancashire WN8 9TUUnited KingdomTel: 44-16-95-52600Fax: 44-16-95-52693

VenezuelaManufacturas PetrolerasVenezolanas S.A.KM 7 Carretera AEl Mojan Calle 18,#15B355 ZONAMaracaibo Edo Zulia, VenezuelaTel: 58-61-579-762 or 070Fax: 58-61-579-461

U.S. Headquarters

Stratford, Connecticut250 E. Main Street Stratford, CT 06614-5145Tel: (203) 378-8281Fax: (203) 385-0499

U.S. Sales Offices

Chicago, Illinois400 W. Lake StreetSuite 318Roselle, IL 60172-3573Tel: (630) 980-9030Fax: (630) 980-9440

Stratford, Connecticut250 East Main Street Stratford, CT 06614-5145Tel: (203) 385-0670FAX: (203) 385-0756

Houston, Texas3838 North Sam Houston Parkway EastSuite 120Houston, TX 77032Tel: (281) 590-1092Fax: (281) 590-7100

Los Angeles, California3931 MacArthur Blvd.Suite 202Newport Beach, CA 92660Tel: (949) 852-8948Fax: (949) 852-8971

Mobile, Alabama851 South Beltline Highway Suite 402, 4th FloorMobile, AL 36606Tel: (334) 473-1692Fax: (334) 473-1782

International Headquarters

Stratford, Connecticut250 E. Main StreetStratford, CT 06614-5145Tel: (203) 378-8281Fax: (203) 385-0357

International Operations

BrazilDresser Industria eComercio Ltda.Divisao Manometros WillyRua SenadorVergueiro No. 43309521-320 Sao Caetano do SulSao Paulo, BrazilTel: 55-11-453-5477Fax: 55-11-453-8710

CanadaDresser Canada, Inc.2135 Meadowpine Blvd.Mississauga,Ontario L5N 6L5CanadaTel: 905-826-8411Fax: 905-826-9106

ChinaDresser Trading Room 2403, 24th FloorCITIC Bldg.19 Jianguo Menwai St.Beijing, P.R.C. Tel: 86-10-6500-3139Fax: 86-10-6512-0300

FranceDresser Europe GmbHDivision Instrumentation74, Rue d’ ArceuilF-94578, Silic 265,FranceTel: 33-01-49-79-22-59Fax: 33-01-46-86-25-24

GermanyDresser Europe GmbHPostfach 11 20Max-Planck-Str. 1D-52499 BaesweilerGermanyTel: 49-2401-8080Fax: 49-2401-7027

72

Consult factory for guidance in product selectionPhone (203) 385-0217, Fax (203) 385-0602 or visit our web site at www.ashcroft.com

STANDARD RANGESPressure Compound

psi psi

0/15 30 in.Hg/15 psi 0/30 30 in.Hg/30 psi 0/60 30 in.Hg/60 psi 0/100 30 in.Hg/100 psi 0/160 30 in.Hg/150 psi 0/200 30 in.Hg/300 psi 0/300 0/400 Vacuum 0/600 30/0 in.Hg 0/800 34/0 ft H2O 0/1000 0/1500 0/2000 0/3000 0/5000 0/10,000 0/20,000 0/30,000

BOURDON SYSTEM SELECTION Ordering Bourdon Tube & Tip Material(1) Socket Tube Range Selection NPT Code (all joints TIG welded except “A”) Material Type Limits (psi) Conn.(2)

A Phosphor Bronze

A Phosphor Bronze

A Brass C-Tube 12/1000 1/4/4/ , 1⁄1⁄1 2⁄2⁄ Tube-Brass Tip, Silver BrazedA Tube-Brass Tip, Silver BrazedA

R 316L stainless steel 1019 steel C-Tube 12/1500 1⁄1⁄1 4⁄4⁄ ,1⁄1⁄1 2⁄2⁄

Helical 2000/20,000 1⁄1⁄1 4⁄4⁄ ,1⁄1⁄1 2⁄2⁄

S 316L stainless steel 316L stainless steel C-Tube 12/1500 1⁄1⁄1 4⁄4⁄ ,1⁄1⁄1 2⁄2⁄

Helical 2000/20,000 1⁄1⁄1 4⁄4⁄ ,1⁄1⁄1 2⁄2⁄

P(3) K Monel Monel 400 C-Tube 15/1500 1⁄1⁄1 4⁄4⁄ ,1⁄1⁄1 2⁄2⁄

Helical 2000/30,000 1⁄1⁄1 4⁄4⁄ ,1⁄1⁄1 2⁄2⁄ (4)

Type 1279 Duragauge® pressure ® pressure ®

gauge is offered in 41/2/2/ ˝ phenolic case for superior chemical and heat resistance. Solid-front case design with blow-out back for safety. Dry, liquid-fi lled, hermetically sealed, weatherproof or PLUS! options avail-able. Field convertible to liquid-fi ll with conversion kit (detailed on page 243). All case styles provide full tem-perature compensation.

• 41/1/1 2/2/ ˝ full-size bourdon tube• Patented Duratube™ with as-welded-

tube construction controls stress for longer life

• “Round Cap Tip” construction lowers stresses for longer life

• Easily adjustable, self-locking micrometer pointer

• Burn-resistant phenol turret case• Exclusive Tefl on coated 400 series

stainless steel rotary movement for longer life

• New PLUS!™• New PLUS!™• New PLUS! Performance Option:™ Performance Option:™

- Liquid-fi lled performance in a dry gauge

- Fights vibration and pulsations without liquid-fi lled headaches

MADE IN U.S.A.

Duragauge® Pressure Gauge Type 1279, ASME B 40.1 Grade 2A (±0.5% of span)

(1) For selection of the correct bourdon system material, see the media application table on page 243.(2) Other connections available on application.(3) Use for applications where NACE standard MR-01-75 is specifi ed.(4) 30,000 psi range supplied with 1⁄1⁄1 4⁄4⁄ high pressure connection, 1⁄1⁄1 2⁄2⁄ NPT optional.

NOTE: Equivalent standard kg/cm2, and kPa metric ranges are available.

(*) “S” denotes solid front case design

TO ORDER THIS 1279 DURAGAUGE:

Select: 45 1279 SS* 04L XXX 2000#Select: 45 1279 SS* 04L XXX 2000#1. Dial size–41⁄1⁄1 2⁄2⁄ ˝2. Case type–1279 Ring–threaded reinforced polypropylene 3. Bourdon system selection ordering code 4. Connection–1⁄1⁄1 4⁄4⁄ NPT (02), 1⁄1⁄1 2⁄2⁄ NPT (04), Lower (L), Back (B)5. Optional features–see page 2396. Standard pressure range 7. Accessories–see pages 233-238

- See pages 6-7 for details- Order as option XLL

• Epoxy-coated system for superior corrosion resistance

180

Consult factory for guidance in product selectionPhone (203) 385-0217, Fax (203) 385-0602 or visit our web site at www.ashcroft.com

Overtemperature Limits

Top of Range °F

up to 250 100% of span

250/550 50% of span

550/1000 800°F **

Case Size Stem Stem Lengths Temperature Range AvailableCase Size Stem AvailableCase Size Stem

“S” Dial Code Style “S”Style “S”

Connection Code Location Code Length Code °F* °/Div. Fig. °C °/Div. Fig.

Code (inches) Fahrenheit °/Div.

Fahrenheit °/Div.

Inter. Celsius °/Div.

Inter. Celsius °/Div.

Inter.

Plain 40 Rear R –80/120 2 20

–50/50 1 10

2˝ 20 Pointed Plain 50 Rear R 21⁄1⁄1 2⁄2⁄ 025 –20/120†† –20/120 2 20

1⁄1⁄1 4⁄4⁄ NPT 60 Rear R 4 040 30/130†† 1 10 0/50†† 1 5

1⁄1⁄1 2⁄2⁄ NPT Union 42 Everyangle E

6 060 0/200 20 0/100 1 10

3˝ 30 EI 1⁄1⁄1 2⁄2⁄ NPT 60 9 090 0/250 2 10/150 Everyangle E

NPT 60 9 090 0/250 2 10/150 Everyangle E

2 20

1⁄1⁄1 2⁄2⁄ NPT 60 Rear R 12 120 50/300 0/200

Lower L 15 150 50/400 50 0/300

1⁄1⁄1 2⁄2⁄ NPT Union 42 Everyangle E

18 180 50/550 5 50/450**† 5 50

5˝ 50 1⁄1⁄1 2⁄2⁄ NPT 60 24 240 200/700† 100/500**† Everyangle E

NPT 60 24 240 200/700† 100/500**† Everyangle E

1⁄1⁄1 2⁄2⁄ NPT 60

Rear R 100/800† 10 100

Lower L 200/1000**†

Select: 30 EI 60 R 040 0/250°F XNH1. Case Size: 3˝ Code 302. Style: Code EI3. Stem Conn: 1⁄1⁄1 2⁄2⁄ NPT Code 604. Stem Location: Rear Code R5. Stem Length: 4˝ Code 0406. Range: Code 0/250°F7. Options: Stainless Steel Tag (see Page 198)

• Hermetically sealed

• External adjustment

• Maxivision® dial® dial®

• ±1% full-span accuracy(ASME B40.3 Grade A)

• All-welded stainless steel construction

• Silicone on the coil provides vibration dampening and superior time response

• Heavy-duty glass standard; plastic or shatterproof glass optional

• Limited fi ve-year warranty

SELECTION TABLE

TO ORDER THIS EI SERIES BIMETAL THERMOMETER:

MaximumOvertemperature

** Dual scale ranges available for all standard °F ranges (3˝ and 5˝ case only)

** Satisfactory for continuous service up to 800°F or 425°C. Can be used for intermittent service from 800 to 1000°F, or 425 to 500°C.

Use Ashcroft Duratemp thermometers for ranges above and below those listed above.†† Minimum stem length for these ranges is 4˝.†† Minimum stem length for lower connection and Everyangle is 4˝.

Thermowells must be used on all pressure or velocity applications, to protect the stem of thermometer from corrosion and physical damage, and to facilitate removal of the thermometer without disturbing the process.Maximum ambient temperature is 200°F (95°C).

This series has a hermetic seal and an external adjustment in the rear of the case. As with other Ashcroft® industrial bimetal thermom-® industrial bimetal thermom-®

eters, it has a Maxivision® dial which ® dial which ®

eliminates parallax by placing the pointer on the same plane as the graduations. The connection locations are rear, lower, and Everyangle.™ Everyangle.™ Everyangle.

The hermetic seal prevents entry of moisture into the casing, thus mini-mizing the possibility of icing or fog-ging inside the case. The window stays clear, and with the Maxivision dial, precise readings are certain.

MADE IN U.S.A.

Bimetal ThermometersSeries EI, ASME B40.3 Grade A (±1% of span)

SECTION 4 Test Documents