Emerson PENBERTHY K3 Series, PENBERTHY K3A, PENBERTHY K3B, PENBERTHY N6 Series Installation, Operation And Maintenance Instructions
PENBERTHY SERIES K3 GAGECOCKS
INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS
Before installation these instructions must be read fully and understood
PRODUCT WARRANTY
Emerson warrants its Penberthy products
as designed and manufactured to be free
of defects in the material and workmanship
for a period of one year after the date of
installation or eighteen months after the date
of manufacture, whichever is earliest. Emerson
will, at its option, replace or repair any products
which fail during the warranty period due to
defective material or workmanship.
TABLE OF CONTENTS
Product warranty ................................................ 1
1 About the manual..................................... 2
2 Introduction ............................................. 2
2.1 Features and specifications ........................ 2
2.2 Design ratings at maximum and minimum
operating temperatures .............................. 2
2.3 Application data ........................................... 2
3
Inspection and performance confirmation
3.1 Receiving inspection .................................... 3
3.2 User's rating inspection .............................. 3
4 Installation ............................................... 3
4.1 Mounting ....................................................... 3
4.2 Sight glass installation ................................ 3
4.3 Guard rod installation .................................. 4
5 Operation ................................................. 4
5.1 Pre-operational check ................................. 4
5.2 Hydrostatic test ............................................ 4
5.3 Operating ...................................................... 4
6 Maintenance ............................................ 4
6.1 Preventative maintenance ........................... 4
6.2 Maintenance procedures ............................ 4
7 Removal - disassembly - reassembly ..... 5
7.1 Disassembly ................................................. 5
7.2 Reassembly .................................................. 5
8 Disposal at end of useful life ................... 5
9 Telephone assistance .............................. 5
10 Exploded parts diagram .......................... 6
.. 3
Prior to submitting any claim for warranty service,
the owner must submit proof of purchase to
Emerson and obtain written authorization to
return the product. Thereafter, the product shall
be returned to Emerson with freight prepaid.
This warranty shall not apply if the product has
been disassembled, tampered with, repaired
or otherwise altered outside of the Emerson
factory, or if it has been subject to misuse,
neglect or accident.
The responsibility of Emerson hereunder
is limited to repairing or replacing the
product at its expense. Emerson shall not be
liable for loss, damage or expenses
directly or indirectly to the installation or use
of its products, or from any other cause or
for consequential damages. It is expressly
understood that Emerson is not responsible
for damage or injury caused to other products,
buildings, personnel or property, by reason of
the installation or use of its products.
This is Emerson's sole warranty and in lieu of
all other warranties, expressed or implied which
are hereby excluded, including in particular all
Warranties of merchantability or fitness for a
particular purpose.
related
Tables and figures
Table 1 Table 2 -
Figure 1 - Exploded parts diagram ................... 6
valves.emerson.com
Design ratings
Tubular glass ratings
.................................... 2
........................ 3
This document and the warranty contained
herein may not be modified and no other
warranty, expressed or implied, shall be made
by or on behalf of Emerson unless made in
writing and signed by the company's general
manager or director of engineering.
© 2017 Emerson. All Rights Reserved. VCIOM-04035-EN 17/05
PENBERTHY SERIES K3 GAGECOCKS
INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS
1 ABOUT THE MANUAL
This manual has been prepared as an aid and
guide for personnel involved installation or
maintenance. All instructions must be read and
understood thoroughly before attempting any
installation, operation or maintenance.
Safety instructions
Emerson does not have any control over the
manner in which its gagecock set is handled,
installed, or used and Emerson cannot and does
not warrant or guarantee that a gagecock set is
suitable for or compatible with the user's specific
application.
CAUTION
Failure to follow any instruction could possibly
result in a malfunction of the gagecock with
resulting sudden release of pressure, property
damage or physical injury.
2 INTRODUCTION
2.1 Features and specifications
Penberthy Series K3 tubular glass gagecocks
are supplied in pairs (upper and lower)
and are designed to house each end of a
transparent sight glass tube. This gagecock/
glass combination forms a gage that accurately
indicates liquid level as well as liquid
characteristics.
Standard features of K3 gagecocks in non
steam-water applications are: a ball check
shut-off to stop leakage of contained fluid in
case of accidental gage glass breakage, integral
bonnet, integral drain cock and handwheel.
CAUTION
Under no circumstances should K3 gagecocks be
used for steam-water applications unless they are
equipped with one of these optional features. Use
of standard K3 gagecocks without these features
may result in sudden release of pressure, leakage
of contained fluid, property damage or physical
injury.
2.2 Design ratings at maximum and minimum
operating temperatures (see Table 1)
To determine the maximum allowable working
pressure for a specific temperature within the
design limits stated below, the user should
refer to relevant technical data sheets or, when
provided, the specifically stated design limits on
a product proposal.
2.3 Application data
Note: for specific application data, within the
above ranges, the user should consult the
product proposal for the specific model and
size gagecock set or should request the supply
of the applicable technical data sheet.
WARNING
Under no circumstances should these design
ratings or application data be exceeded.
Exceeding design ratings or application data may
cause severe physical injury or property damage.
Safety instructions
Under most circumstances, Series K3
gagecocks are not recommended without a
ball check shut-off. Gagecocks without the ball
check shut-off feature will not stop leakage of
contained fluid in the event of accidental tubular
glass breakage. However, in circumstances
where the fluid being gaged tends to surge in a
rapid manner, the ball checks could tend to give
a false level reading or seat accidentally.
Series K3 gagecocks are not suitable for
steam-water applications unless they are
furnished with one of the following optional
features:
1. Non-automatic gagecocks – ball checks
removed from both upper and lower
gagecocks.
2. Automatic gagecocks – vertical ring ball
check and ball inspection plug in the lower
gagecock. The upper gagecock is equipped
with a horizontal ball check and a leaky ball
seat formed in the body.
TABLE 1 - DESIGN RATINGS
Material Model Maximum allowable working pressure Maximum steam pressure
Bronze K3A 225 psig [1.55 MPa] at -20°F [-29°C] to +100°F [38°C]
150 psig [1.03 MPa] at 500°F [260°]
K3B 500 psig [3.45 MPa] at -20°F [-29°C] to +100°F [38°C]
300 psig [2.07 MPa] at 550°F [288°C]
Pressure/temperature ranges in above table are subject to the limitations of the tubular glass.
See Table 2.
175psig [1.21 MPa]
360 psig [2.48 MPa]
2
PENBERTHY SERIES K3 GAGECOCKS
INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS
TABLE 2 - TUBULAR GLASS - RATINGS, ⅝" (16 mm) AND ¾" (19 mm) OD
Vessel tappings ctr. to ctr. Distance
in
inches [mm] psig [MPa] psig [MPa] psig [MPa] psig [MPa] psig [MPa] psig [MPa]
10 [ 254] 410 [2.83] 600 [4.14] 340 [2.34] 310 [2.14] 345 [2.38] 275 [1.90]
15 [ 381] 385 [2.65] 600 [4.14] 310 [2.14] 280 [1.93] 325 [2.24] 265 [1.83]
20 [ 508] 355 [2.45] 600 [4.14] 285 [1.97] 265 [1.83] 315 [2.17] 260 [1.79]
25 [ 635] 300 [2.07] 580 [4.00] 260 [1.79] 250 [1.72] 300 [2.07] 250 [1.72]
30 [ 762] 275 [1.90] 550 [3.80] 230 [1.59]
35 [ 889] 240 [1.65] 500 [3.45] 200 [1.38]
40 [1016] 210 [1.45] 420 [2.90] 180 [1.24]
45 [1143] 200 [1.38] 360 [2.48] 170 [1.17]
50 [1270] 180 [1.24] 340 [2.34] 160 [1.10]
55 [1397] 150 [1.03] N/A 140 [0.97]
60 [1524] 140 [0.97] N/A 120 [0.83]
65 [1651] 125 [0.86] N/A 100 [0.69]
70 [1778] 100 [0.69] N/A 90 [0.62]
N/A – Not Available
High pressure Heavy wall Red line High pressure Heavy wall Red line
Up to 150°F [66°C] From 150°F [66°C] thru 400°F [204°C]
3 INSPECTION AND PERFORMANCE
CONFIRMATION
3.1 Receiving inspection
Upon receipt of a gagecock set, check all
components carefully for damage incurred in
shipping. If damage is evident or suspected,
do not attempt installation. Notify the carrier
immediately and request a damage inspection.
3.2 User’s rating inspection
The user should confirm that:
1.
The gagecock set model number and the
pressure/temperature rating conforms to the
description on the user’s purchase order.
2. The operating conditions described in
the purchase order agree with the actual
operating conditions at the installation site.
3.
The actual operating conditions at the
installation site are within the application data
shown on the applicable technical data sheet
or product proposal.
4. The materials of construction of the
gagecock set are compatible with both
the contained fluid and the surrounding
atmosphere in the specific application.
Safety instructions
If the size, model, or performance data of the
gagecock set as received does not conform with
any of the criteria above, do not proceed with
installation. Contact an authorized Penberthy
distributor for direction.
4 INSTALLATION
Installation should only be undertaken by
qualified personnel who are familiar with this
equipment and have read and understood all
of the instructions in this manual. The user
should refer to applicable technical data sheets
or product proposal to obtain dimensional
information for the specific size and model
gagecock set.
4.1 Mounting
1. Prior to actual installation, turn the
handwheel or lever of each gagecock
clockwise until the stem closes against the
seat.
2. Mount upper and lower gagecocks to the
vessel using PTFE tape on all male tapered
pipe thread connections.
3. Tighten vessel connections to a pressure
tight joint making certain that sight glass
connections are aligned vertically and
to vessel centers as called for on the
application specification.
4.2 Sight glass installation
1. Turn upper gagecock counterclockwise
(approx. ⅛ turn).
2. Loosen glass packing nut to insure there is
no compressive force on glass packing.
3. Insert sight glass in upper gagecock sight
glass connection.
4. Tighten upper gagecock to original position
while holding sight glass in position with
upward force to insure its clearing of lower
sight glass connection. Check vertical
alignment of gagecocks.
5.
Loosen glass packing nut on lower gagecock
and pull glass down into lower gagecock
sight glass connection to a positive stop.
6. Tighten upper and lower glass packing nuts.
Note: in some circumstances, it may be
necessary to remove the glass packing nut,
glass packing gland and glass packing, and
mount them on the sight glass prior to insertion
of glass in upper and lower gagecock bodies.
See Figure 1 for proper assembly sequences.
3
PENBERTHY SERIES K3 GAGECOCKS
INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS
4.3 Guard rod installation
Guard rods (four required) are assembled
downward through upper gagecock with
swaged portion on rods at the top. Bottom of
rods are positioned into respective holes in the
lower gagecock rod star.
5 OPERATION
5.1 Pre-operational check
1. Assure that all installation procedures have
been completed.
2. Check to determine that all connections are
pressure tight.
5.2 Hydrostatic test
1. Take all precautions necessary to handle
the possibility of leakage during the test.
2. Hydrostatic pressure test all installations to
100 psig (690 kPaG) and correct any leakage
before proceeding.
5.3 Operating
Gagecock assemblies should be brought
into service slowly. The tubular glass used in
Penberthy gagecock sets is tempered and can
stand minimal thermal shock and mechanical
stress.
To avoid excessive thermal shock or
mechanical stress on the tubular glass, the
connecting gagecocks should be opened
slightly, and the tubular glass temperature and
pressure allowed to equalize slowly with the
vessel.
If the gagecocks are furnished with ball checks,
the gagecocks must be opened all the way after
the pressure and temperature have equalized
to permit operation of the automatic ball check
in the event of tubular glass breakage.
6 MAINTENANCE
Maintenance should only be undertaken by
qualified, experienced personnel who are
familiar with this equipment and have read and
understood all the instructions in this manual.
During system shut down, the gagecocks
should be left open to permit the gage to lose
pressure and cool with the rest of the system.
Failure to leave the gagecocks open during
system shut down will trap high-pressure fluid
in the gage.
CAUTION
Do not proceed with any maintenance unless the
gage has been relieved of all pressure or vacuum,
has been allowed to reach ambient temperature
and has been drained or purged of all fluids.
Failure to follow these instructions may result in
physical injury or property damage.
6.1 Preventative maintenance
The user must create maintenance schedules,
safety manuals and inspection details for each
specific installation of a gagecock set.
For purposes of maintenance on all
installations, the gagecocks should be
evaluated regularly by the user for signs of:
1. leakage around stem area.
2. internal stem leaks.
3. leakage around stuffing box connection.
4. internal or external corrosion.
The user must determine an appropriate
maintenance schedule necessary for his or her
specific application upon evaluation of their own
operating experience. Realistic maintenance
schedules can only be determined with full
knowledge of the services and application
situations involved.
6.2 Maintenance procedures
1. Stem packing leakage can often be stopped
by tightening the stem packing nut. If
leakage persists, the stem packing should
be replaced by following steps 'a' through 'c'
of Disassembly and step 'd' of Reassembly.
2.
Signs of an internal stem leak are an
indication of a worn or damaged stem or seat.
a. To replace the stem, follow Disassembly
steps 'a' through 'd' and Reassembly
steps 'a' through 'd'.
b. To renew the seat surface, follow
Disassembly steps 'a' through 'd'. Renew
seat by using a fine lapping compound
and a mandrel the same size, shape and
seat angle as the stem. Flush gagecock
body clean and reassemble by following
steps 'a' and 'd' of Reassembly.
Note: series K3 gagecocks have an integral
seat. Gagecock body must be replaced when
seat becomes worn or damaged beyond repair.
3. Signs of leakage around the stuffing box
indicate worn out glass packing or improper
compression of glass packing. To replace
glass packing, follow Disassembly steps 'a',
'b' and steps 'e' through 'j' and Reassembly
steps 'a', 'b', and 'e' through 'k'. In the event
of improper compression, leakage can be
stopped by tightening gage coupling nut.
4. Signs of internal or external corrosion
could be an indication of a misapplication.
An investigation should be carried out
immediately to determine the cause of
the problem. It is the user's responsibility
to choose a material of construction
compatible with both the contained fluid and
the surrounding atmosphere in the specific
application.
5. For broken sight glass replacement, follow
Disassembly steps 'a', 'b', and 'e' through
'j' and Reassembly steps 'a', 'b' and 'e'
through'k'.
Safety instructions
New glass packing must be used when
replacing glass.
4
PENBERTHY SERIES K3 GAGECOCKS
INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS
7 REMOVAL - DISASSEMBLY - REASSEMBLY
CAUTION
Do not proceed with the disassembly of a gage
unless the gagecock has been relieved of all
pressure or vacuum, has been allowed to reach
ambient temperature and has been drained
or purged of all fluids. Failure to follow these
instructions may result in physical injury or
property damage.
7.1 Disassembly
a. Close upper and lower gagecocks.
b.
Open draincock and allow gagecocks to drain.
c. Loosen and remove stem packing nut and
old stem packing.
d. Remove bonnet nut and bonnet/stem
assembly.
e. Remove guard rods if present.
f. Loosen glass packing nuts on both upper
and lower gagecocks.
g. Slide sight glass upward into upper
gagecock until bottom of tubular glass
clears the stuffing box connection on the
lower gagecock.
h. While holding the tubular glass in this
upward position, rotate upper gagecock
counterclockwise (approx. ⅛ turn) to allow
clearance to remove sight glass from upper
gagecock.
i. Remove sight glass from upper gagecock.
j. Remove glass packing nut, glass packing
gland and glass packing from both the
upper and lower gagecocks.
7.2 Reassembly
a. Refer to exploded view Figure 1.
b. Prepare for installation of new packing by
cleaning all packing chambers and glands
of upper and lower gagecocks.
c. Install new bonnet/stem assembly and
tighten bonnet nut.
d. Install new stem packing and tighten stem
packing nut into place.
e. Replace glass packing nut, glass packing
gland and new glass packing on each end of
tubular glass.
f. With upper gagecock turned ⅛ turn
counterclockwise from vertical insert
one end of sight glass into stuffing box
connection in upper gagecock to sufficient
depth to insure a clearance of lower
gagecock glass packing nut.
g. Tighten upper gagecock to original position
holding sight glass in place with upward
force to insure it's clearing the lower sight
glass connection. Check vertical alignment
of gagecocks.
h. Slide sight glass down into lower gagecock
sight glass connection to a positive stop.
i. Tighten glass packing nuts.
j. Close both gagecocks by turning handwheel
or lever clockwise until stem seats.
k. Replace guard rods.
Refer to Section 5 for operation of gagecock
when returned to service.
8 DISPOSAL AT END OF USEFUL LIFE
Penberthy gagecocks are used in a variety of
fluid applications. By following the appropriate
federal and industry regulations, the user
must determine the extent of preparation and
treatment the gagecock must incur before its
disposal. A Material Safety Data Sheet (MSDS)
may be required before disposal services accept
certain components.
Metal, glass and polymers should be recycled
whenever possible. Refer to order and
relevant technical data sheets for materials of
construction
9 TELEPHONE ASSISTANCE
If you are having difficulty with your SeriesK3
gagecock, contact your local Penberthy
distributor. You may also contact the factory
direct at (956) 430-2500 and ask for an
applications engineer. So that we may assist
you more effectively, please have as much of the
following information available as possible when
you call:
- Model #
- Name of the company from whom you
purchased your gagecock
- Invoice # and date
- Process conditions (pressure, flow rates, tank
shape, etc)
- A brief description of the problem
- Trouble shooting procedures that failed
If attempts to solve your problem fail, you may
request to return your gagecock to the factory
for intensive testing. You must obtain a Return
Authorization (R.A.) number from Emerson
before returning anything. Failure to do so will
result in the unit being returned to you without
being tested, freight collect. To obtain an R.A.
number, the following information (in addition to
that above) is needed:
- Reason for return
- Person to contact at your company
- 'Ship-to' address
There is a minimum charge for evaluation
of non-warranty units. You will be contacted
before any repairs are initiated should the cost
exceed the minimum charge. If you return a
unit under warranty, but it is not defective, the
minimum charge will apply.
5
PENBERTHY SERIES K3 GAGECOCKS
INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS
10 EXPLODED PARTS DIAGRAM
FIGURE 1
PARTS LIST
Ref # Item
40 Rod
48 Glass
37 Nut, glass packing
36 Gland, glass packing
34 Packing, glass
33 Star
14 Ball retainer
15 Ball
11 Body
17 Stem
20 Bonnet
21 Nut, bonnet
18 Retainer, stem packing
25 Packing, stem
26 Nut, stem packing
28 Handwheel
44 Cock
SPARE PARTS
Ref # Item Min. qty.
18 Retainer, stem packing 2
25 Packing, stem 2
26 Nut, stem packing 1
34 Packing, glass 2
36 Gland, glass packing 2
37 Nut, glass packing 1
48 Glass 1
Recommended maximum quantities should provide
spare parts for 10% of the gagecocks in service.
6
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