Manual No.

3111330-07011OM-Rev A
Operator’s Manual
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OPERATOR’S MANUAL
K80-3705 Pulsation Dampener PAGE
1

HYDRIL® K20-5000
PULSATION DAMPENER

Pressure Control Equipment

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K20-5000 Pulsation Dampener PAGE

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K20-5000 Pulsation Dampener

Complete Assembly
Hydril Part No. 3111330-07011

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

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

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

©2000 Hydril Company • Printed In The U.S.A., August 2000 • All Rights Reserved
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2 K20-5000 Pulsation Dampener

PREFACE

Hydril makes no warranties of any kind, expressed or This manual makes recommendations only. The cus-
implied, including any warranty of mechanical fitness tomer is at all times responsible for actual disassembly,
for any particular purpose that the work performed pur- inspection, re-assembly and testing of the pulsation
suant to this manual will be free from defects in work- dampener body. The customer is also solely respon-
manship or material. sible for providing competent and qualified persons;
equipment and facilities to perform such operations; and
Hydril retains for itself all proprietary rights in and to all for workmanship and safety.
designs, engineering details, data and procedures set
forth herein. This manual is intended for the sole use of If at any time the customer is unable to understand the
Hydril customers and they shall strictly control copying recommendations made in this manual or is unable to
of same, as this manual and all copies thereof may be follow those recommendations, they should consult the
recalled by Hydril at any time. nearest Hydril location.
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CONTENTS

PAGE

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

SECTION 1.0 – INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SECTION 2.0 – DISASSEMBLY ............................................. 6

SECTION 3.0 – ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SECTION 4.0 – MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

SECTION 5.0 – PRECHARGE ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

SECTION 6.0 – PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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4 K20-5000 Pulsation Dampener

1.0 INSTALLATION

Charging Valve Nitrogen Bottle

CAUTION: Do not attempt to precharge any K-Series
pulsation dampener prior to mounting the unit into the pump
piping system.
Charging
Hose Assy.
The Hydril K20-5000 Pulsation Dampener should be
mounted in the vertical position (refer to Figure 1-1 for Figure 1-2. Precharge Hookup
mounting options) with the mating flange connection at
the bottom. The bottom connection for this K20-5000 is a WARNING: ALWAYS PRECHARGE WITH ZERO
4 -1/16” API 5000 RTJ. The discharge dampener should PRESSURE ON THE SYSTEM AND ALWAYS
be mounted as close as possible to the discharge port of PRECHARGE WITH NITROGEN.
the pump. If possible, it is advantageous that the damp-
ener be mounted in such a way that the fluid stream is A. General Precharging Instructions
directed towards the fluid opening. 1. The charging valve and pressure gauge are located
under the valve guard and are exposed by remov-
A. Mounting ing the valve guard.
1. Install stud bolts in the replaceable bottom plate. 2. Before precharging the dampener make sure all
2. Position dampener on gasket and mating flange so cover stud nuts are tightened evenly and charging
that the space between flange and bottom connec- valve and pressure gauge seal nuts are firmly
tion is totally equal around the circumference. seated on the dampener.
3. Install one lubricated nut on each stud and tighten 3. Precharging is accomplished by connecting one end
one turn at a time until dampener is firmly in place. of the charging hose assembly to a standard com-
Assure that space between dampener and flange mercially available NITROGEN bottle and the other
is equal. end to the charging valve located at the top of the
4. Cross tighten nuts to the proper torque (725 - 800 pulsation dampener (Refer to Figure 1-3).
lb-ft or 980 - 1080 N•m). 4. Precharge from a standard commercially available
nitrogen bottle equipped with a pressure regulator.
B. Precharging (NITROGEN ONLY) 5. For those applications where higher precharge pres-
The correct precharge is vital for maximizing efficiency of sures are required, a gas booster pump is avail-
the pulsation dampener. Generally, precharge pressure able; for example, Haskell International Inc.
is based on the average operating pressure of the sys- 6. Open bottle regulator valve until recommended
tem, but precharge can be affected by other system pa- precharge pressure shows on regulator gauge.
rameters; for example. the use of MWD tools. For these 7. Slowly open charging valve on dampener. Allow
applications, consult qualified Hydril personnel for correct pressure to increase in the dampener until damp-
precharging instructions. ener pressure gauge reads the specified precharge

Horizontal Discharge Vertical Discharge

Dampener Dampener

Mounting Flange Mounting Flange

Discharge Line Tee Discharge Line Tee

Long Radius Elbow

Pump
Discharge Flange
Pump Discharge Flange
Figure 1-1. Mounting Options
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Valve Guard
With Lifting Eye

Pressure
Charging Valve Gauge

Cover Plate

Diaphragm
Diaphragm
Stabilizer

Body

Gasket

Bottom Plate

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

pressure. This process will normally take 5 to 15 D. Leak Detection

minutes. Dampener gauge and regulator gauge Apply leak detection fluid at all connections around valve,
should read the same and be equal to the specified pressure gauge, cover, body contact surfaces, and studs.
precharge pressure. Observe carefully for bubbles that indicate leaks. If any
8. Close the charging valve and tighten. Then, close indications are found, check system for loose connections
regulator valve at nitrogen bottle. Remove charg- and retighten. Allow the nitrogen gas in the dampener to
ing hose, replace dust plug in charging valve, and come to ambient conditions (approximately one-half hour)
replace valve guard. and recheck the precharge pressure.

C. Precharge Recommendations Adjust the precharge pressure as required. After precharge

For normal operating conditions, set the precharge pres- pressure has stabilized at specified pressure, close valves,
sure at 50 to 70 percent of the average operating dis- remove charging hose, and replace valve guard. Damp-
charge pressure not to exceed 5000 PSI. The precharge ener is now ready for operation.
pressure can be as low as 30 percent or as high as 75
percent of system operating pressure. However, these
precharge settings may shorten diaphragm life.
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6 K20-5000 Pulsation Dampener

2.0 DISASSEMBLY

A. Disassembly Procedure
Refer to Figure 2-1. sult your nearest Hydril representative for cor-
1. Shut down pumps and remove system pressure rective action.
from dampener.
2. Remove valve guard. B. Cleaning and Inspection Procedure
3. Open charging valve and bleed off all precharge 1. Flush diaphragm body, clean and remove scale and
pressure. CAUTION: System and vessel pressure other foreign material.
must be at zero psi before removing charging valve 2. Inspect inside of dampener body for excessive pit-
and pressure gauge or loosening cover or flange ting. Corrosion or wear. If these conditions exist,
bolts. consult your nearest Hydril representative.
4. Remove charging valve and gauge from cover. 3. Mild pitting or scaling can be removed with applica-
5. Check for system fluid in gauge and valve ports. tion of light duty emery cloth. Inside of dampener
6. Loosen all cover stud nuts, but do not remove. must be free of burrs and debris.
Make sure the cover plate is not pushing upwards
against nuts. This would indicate that pressure has
not been completely removed from dampener.
7. After all pressure is removed from dampener, re-
move nuts from studs.
8. Attach valve guard to cover plate to use as a lifting
eye
9. Remove cover
10. If dampener is equipped with a stabilizer, remove
cap screw, lock washer and stabilizer plate. Re-
move stabilizer so the diaphragm may be folded
and removed from the body.
11. Pull neck portion of diaphragm loose from one side
of dampener. Push bottom of diaphragm down, fold
diaphragm or place bar between dampener body
and diaphragm below the diaphragm mid-section
to assist folding and removal of diaphragm from
body.
12. If the bottom plate is to be removed for replace-
ment or inspection, follow the procedure below:
a. Verify cover is attached and all stud nuts are
snug.
b. Attach valve guard to cover to use as lifting eye.
c. Remove all flange and stud nuts at bottom con-
nection.
d. Remove dampener from flange connection. Set
stud nuts and gaskets aside and save for rein-
stallation.
e. Remove dirt and debris from bottom plate open-
ing.
f. Remove socket head cap screws that hold bot-
tom plate in place. Set aside and save.
g. Remove bottom plate from dampener. Remove
gasket and inspect for damage. Set aside and
save if reusable. Replace if damaged.
h. Inspect bottom plate for excessive pitting, cor-
rosion or wear. If these conditions exist, con-
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Valve Guard
With Lifting Eye

Pressure
Charging Valve Gauge

Cover Plate

Diaphragm
Diaphragm
Stabilizer

Body

Gasket

Bottom Plate

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

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8 K20-5000 Pulsation Dampener

3.0 ASSEMBLY

All metal surfaces of the cover plate, body, and bottom

plate which come into contact with the diaphragm must NOTE: Make certain that the neck portion of the
be cleaned carefully before reassembly. Scrape and diaphragm and cover plate is clean and free of
wire brush all surfaces and completely remove any for- any debris, rust, or scale. Coat with a light lu-
eign matter, rust or scale. Refer to Figure 3-1 while bricant prior to installation of cover plate to the
following the procedure below. body.

A. Bottom Plate Gasket Installation E. Cover Plate Installation

1. Place bottom plate gasket in groove of bottom plate. 1. Install cover plate, studs, and lubricated nuts. Cross
tighten by hand or wrench, a few turns at a time,
B. Bottom Plate Installation until cover is firmly seated on the dampener body.
1. Insert bottom plate into body taking care not to pinch Cross tighten to the appropriate torque (2530 - 2630
gasket and align counter bore holes with tapped lb-ft or 3430 - 3570 N•m).
holes in body. Install socket head cap screws and
tighten evenly until bottom plate is snug against F Installation of Charging Valve
body. Torque cap screws to 725 - 800 lb-ft or 980 - 1. Back thread seal nut on valve and thread valve into
1080 N•m. tapped hole.
2. Tighten to 20 ± 5 lb-ft or 27 ± 7 N•m torque
C. Diaphragm Installation 3. If the valve is not facing in the proper direction, take
1. Apply a light coat of a general lubricant (castor oil the following steps:
or equivalent) on diaphragm to aid in installation. a. Rotate forward if less than a ½ turn is required
2. Pull up on neck of diaphragm while pushing dia- to position valve in proper direction.
phragm insert area down. b. Rotate backward if the previous step is not
.3. Take the new diaphragm in the at rest position and possible until the valve is positioned in the
roll one side toward the other forming a crude foot- proper direction ( ½ turn maximum).
ball shape. A thin belt or strap may be helpful in c. After valve is in position, tighten seal nut to 20
holding this shape. ± 5 lb-ft or 27 ± 7 N•m torque.
4. Apply lubricant to the folded diaphragm and insert
it long ways into the body of the dampener as far G. Installation of Pressure Gauge
as possible ( the diaphragm should go over half 1. Install pressure gauge so that the face is positioned
way into the dampener body). in such a manner that it will be visible through the
5. Fold the remainder of the diaphragm into the ves- valve guard opening
sel and allow it to open inside the body. 2. Back thread seal nut on valve and thread valve into
6. Position the diaphragm within the neck of the ves- tapped hole
sel. 3. Tighten to 20 ± 5 ft-lb or 27 ± 7 N•m torque
4. If the gauge is not facing in the proper direction,
D. Stabilizer Installation take the following steps:
1. When stabilizer is used, temporarily install hex a. Rotate forward if less than a ½ turn is required
screw into insert. to position gauge in proper direction
.2. Break vacuum at neck by pulling diaphragm slightly b. Rotate backward if the previous step is not
away from sealing area. possible until the gauge is positioned in the
3. Pull up on hex nut so diaphragm bottom moves up proper direction ( ½ turn maximum)
near neck opening. c. After gauge is in position, tighten seal nut to 20
4. Re-seat diaphragm neck, remove hex screw, and ± 5 lb-ft or 27 ± 7 N•m torque.
install stabilizer.
5. Fold stabilizer with edge down and insert into dia- H. Pressurize Pulsation Dampener
phragm opening. Use precharge instructions in Section 1. Attach valve
6. Assemble stabilizer plate, lock washer, and hex guard, and the pulsation dampener is now ready for
screw through stabilizer and fasten to diaphragm use.
by attaching hex screw to threaded insert.
7. Tighten securely with socket wrench.
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Valve Guard
With Lifting Eye

Pressure
Charging Valve Gauge

Cover Plate

Diaphragm
Diaphragm
Stabilizer

Body

Gasket

Bottom Plate

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

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10 K20-5000 Pulsation Dampener

4.0 MAINTENANCE

A. Precharge C. High Precharge Effects

1. When properly installed and pre-charged, the pul- 1. If the pre-charge is TOO HIGH, the diaphragm in-
sation dampener is virtually maintenance free. sert will rest on the bottom of the dampener, clos-
2. The vessel should be checked periodically for ing off the fluid inlet.
proper precharge and leaks. Unless conditions 2. Until the system pressure exceeds the precharge
such as ambient temperature, operating conditions, pressure, no dampening will take place.
or operating temperatures change, checking every 3. During the time the precharge pressure is nearly
six months should be sufficient. equal with the system pressure, the diaphragm will
bounce on and off the inlet opening which could
B. Low Precharge Effects effect the service life of the diaphragm.
1. If the pre-charge pressure is TOO LOW, the pulsa-
tion dampener will fill with excess fluid, thus losing
some of the working volume of the gas and reduc-
ing dampener efficiency.
2. Additionally, excessive flexing of the diaphragm may
cause premature rubber failure at the neck or equa-
tor of the diaphragm.
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5.0 PRECHARGE ADJUSTMENTS

A. Precharge Low B. Precharge High

1. Original precharge may have been to low. 1. Original precharge may have been to high.
2. Ambient temperature may have decreased. 2. Ambient temperature may have increased. Release
3. Check charging valve for leaks. pressure.
a. Apply leak detection fluid to threads and valve 3. Diaphragm may be trapping pressure (system fluid)
openings. when pump is shut down. This will be indicated by
b. Tighten loose threads, close valve stem, or re- a higher than normal pressure reading on the gauge,
place valve if stem does not close. which is usually of a different value, each time the
4. Check pressure gauge for leaks. pump shuts down. This condition usually occurs
a. Apply leak detection fluid to threads, face, and when the fluid is highly viscous. Installation of a
back cover. diaphragm stabilizer should cure this condition.
b. Tighten loose threads. Replace gauge if leaks CAUTION: If it is determined that any items need
continue. to be replaced or dampener cover removed,
5. Check for leaks between cover and body. PLEASE FOLLOW THE DISASSEMBLY AND AS-
a. Apply leak detection fluid to studs and cover- SEMBLY PROCEDURES.
body contact surfaces.
b. Tighten stud nuts. If leaks persist, remove cover
and clean mating surfaces. Reassemble and
repeat leak test.
6. Check Diaphragm (if all the above fail to find the
leak). If the dampener will not hold precharge pres-
sure, it may be due to nitrogen leaks through the
diaphragm. Check for evidence of fluid at either
charging valve or pressure gauge port hole. CAU-
TION: Make sure dampener pressure is at zero
psig before removing charging valve or pres-
sure gauge. If fluid is present, replace diaphragm.
See Disassembly and Assembly sections.
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6.0 PARTS

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

Item
No. Description Part No. Qty.

1 Body 3111331 1
2 Cover Plate 3111336 1
3 Guard 1005206 1
4 Diaphragm, Hydrogenated 1005208-07 1
* 5 Bottom Plate 3111338-01 1
6 Gasket 1005212-07 1
* 7 Diaphragm Stabilizer 1005213 1
* 8 Stabilizer Plate 1005214 1
* 9 Stabilizer Screw 1005215 1
* 10 Hydril Logo Label 3116004-5 2
11 Lock Washer 1900105-20 1
* 12 Charging Valve, 5000 PSI 1005073-02 1
* 13 Nameplate 3108946-19 1
14 Nut, Lock, Pressure Gauge 1920007-02 1
15 Nut, Lock, Charging Valve 1920007-05 1
16 Nut, Hex Head, Cover Plate 1900035-15 12
17 Cap Screw, Bottom Plate 1900205-20020 8
18 Cap Screw, Guard 1900047-12010 4
19 Drive Screw 1900061-12 4
20 Stud Bolt, Cover Plate 1900096-15062 12
21 Pressure Gauge 1900168-5 1
* 22 Tag, Caution 3103237 1

6.2 Accessories

Charging Hose 1920006-04 1

Pressure Control Hardware Kit 3110796-075 1
* Bottom Connection Kit 1005447-1 1

* Contents of Pressure Control Hardware Kit (one-year recommended spare parts list).
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12

15

21

14

18

20

16

2
19 13
9

11
19 22
8

10

17

Figure 6-1. Typical K20-5000 Series Pulsation Dampener - Cutaway for Part Identification
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K80-3705 Pulsation Dampener PAGE
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Pressure Control Equipment

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