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    Installation ManualSurge and Pulsation Control K-Series Dampeners

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    Manual6804-B

    ManualInstallation

    Surge and Pulsation ControlK-Series Dampeners

    INSTALLATION, OPERATION, MAINTENANCE AND PARTS

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    Installation ManualSurge and Pulsation Control K-Series Dampeners

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    Hydril makes no warranties of any kind, expressed orimplied, including any warranty of mechanical fitness forany particular purpose that the work performed pursuant tothis manual will be free from defects in workmanship ormaterial.

    Hydril retains for itself all propriety rights in and to alldesigns, engineering details, data, and procedures setforth herein. This manuals is intended for the sole use ofHydril customers, and they shall strictly control copying ofsame, as this manual and all copies thereof may berecalled by Hydril at any time.

    PREFACE

    This manual makes recommendations only. Thecustomer is at all times responsible for actual disassem-bly, inspection, reassembly, and testing of the pulsationdampener vessel. The customer also is solely responsiblefor providing competent and qualified persons; equipmentand facilities to perform such operations; and for workman-ship and safety. If at any time the customer is unable tounderstand recommendations made in this manual or isunable to follow those recommendations, they shouldconsult the nearest Hydril location. Refer to Hydril websitewww.hydril.com for complete list of locations, includingaddresses, telephone numbers, and FAX numbers.

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    Installation ManualSurge and Pulsation Control K-Series Dampeners

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

    HYDRIL / P.O. BOX 60458 / HOUSTON, TEXAS 77205TELEPHONE: (281) 449-2000; 1-800-231-0023 (Toll Free in U.S.A. andCanada) / FAX: (281) 985-2828 / Website: www.hydril.com

    2002 Hydril Company LP Rev B Printed In The U.S.A. December 2004 All Rights Reserved

    Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

    1.0 INSTALLATION

    1.1 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.2 Precharging (Nitrogen Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.3 General Precharging Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.4 Precharge Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51.5 Leak Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

    2.0 MAINTENANCE

    2.1 Disassembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.2 Cleaning and Inspection Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.3 Assembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102.4 Performance Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

    3.0 PHYSICAL DATA

    3.1 K10 Series Parts and Materials of Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133.2 K20 Series Parts and Materials of Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193.3 K80 Series Parts and Materials of Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153.4 Coverplate and Mating Flange Bolting Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163.5 Capacity, Pressure, Dimensions, and Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173.6 K-Series Diaphragms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183.7 Storage of Diaphragms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

    CONTENTS

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    Installation ManualSurge and Pulsation Control K-Series Dampeners

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    1.0 INSTALLATION

    CAUTION: Do not attempt to precharge any K-Series pulsa-tion dampener prior to mounting the unit into the pumppiping system.

    The Hydril K-P Series Pulsation Dampener/Surge Stabilizershould be mounted in the vertical position (refer to Figure 1-3 and 1-4 for mounting options) with the mating flange con-nection at the bottom. The discharge dampener should bemounted as close as possible to the discharge port of thepump. If possible, it is advantageous that the dampener bemounted in such a way that the fluid stream is directed to-wards the fluid opening (see Figures 1-3 and 1-4) for maxi-mum performance.

    1.1 Mounting1.1.1 Install stud bolts in the replaceable bottom

    plate.1.1.2 Position dampener on gasket and mating

    flange so that the space between flange andbottom connection is totally equal around thecircumference.

    1.1.3 Install one lubricated nut on each stud andtighten one turn at a time until dampener isfirmly in place. Assure that space betweendampener and flange is equal.

    1.1.4 Cross tighten nuts to the proper torque. Refer tobolting data in Section 3.2.

    1.2 Precharging (NITROGEN ONLY)The correct precharge is vital for maximizing efficiency of thepulsation dampener. Generally, precharge pressure is basedon the average operating pressure of the system, but

    precharge can be affected by other system parameters; forexample. the use of MWD tools. For these applications, con-sult qualified Hydril personnel for correct precharging instruc-tions.

    WARNING: ALWAYS PRECHARGE WITH ZERO PRESSUREON THE SYSTEM AND ALWAYS PRECHARGE WITH NITRO-GEN.

    1.3 General Precharging Instructions1.3.1 The charging valve and pressure gauge are

    located under the valve guard and are exposedby removing the valve guard.

    1.3.2 Before precharging the dampener, make sure allcover stud nuts are tightened evenly andcharging valve and pressure gauge seal nutsare firmly seated on the dampener.

    1.3.3 Precharging is accomplished by connecting oneend of the charging hose assembly to a stan-dard commercially available NITROGEN bottleand the other end to the charging valve locatedat the top of the pulsation dampener (Refer toFigure 1-1).

    1.3.4 Precharge from a standard commerciallyavailable nitrogen bottle equipped with apressure regulator.

    1.3.5 For those applications where higher prechargepressures are required, a gas booster pump isavailable; for example, Haskell International Inc.

    1.3.6 Open bottle regulator valve until recommendedprecharge pressure shows on regulator gauge.

    Figure 1-1. Precharging K Series Dampener

    NitrogenDampener

    Charging Hose Assy. PN:(Refer to Parts List inSection 3.)

    Regulator (Not Partof Charging HoseAssy.)

    Not Part ofCharging HoseAssy.

    Charging Valve PN:(Refer to Parts List inSection 3.)

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    Installation ManualSurge and Pulsation Control K-Series Dampeners

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    Figure 1-2. Typical K-P Series Pulsation Dampener

    1.3.7. Slowly open charging valve on dampener. Allowpressure to increase in the dampener until damp-ener pressure gauge reads the specified pres-sure. This process will normally take 5 to 15 min-utes. Dampener gauge and regulator gaugeshould read the same and be equal to the speci-fied precharge pressure.

    1.3.8. Close the charging valve and tighten. Then, closeregulator valve at nitrogen bottle. Remove charg-ing hose, replace dust plug in charging valve, andreplace valve guard.

    1.4 Precharge RecommendationsFor normal operating conditions, set the precharge pressureat 50 to 70 percent of the average operating discharge pres-sure not to exceed 5000 PSI. The precharge pressure can beas low as 30 percent or as high as 75 percent of system

    operating pressure. However, these precharge settings mayshorten diaphragm life.

    1.5 Leak DetectionApply leak detection fluid at all connections around valve, pres-sure gauge, cover, body contact surfaces, and studs. Ob-serve carefully for bubbles that indicate leaks. If any indica-tions are found, check system for loose connections and re-tighten. Allow the nitrogen gas in the dampener to come toambient conditions (approximately one-half hour) and recheckthe precharge pressure.

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

    Bottom Plate

    Charging ValvePressureGauge

    Valve Guard WithLifting Eye

    Cover Plate

    Diaphragm

    Body

    Gasket

    DiaphragmStabilizer

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    Installation ManualSurge and Pulsation Control K-Series Dampeners

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    Figure 1-3.

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