Penberthy Gagecocks - Series N6, Penberthy-EN Manuals & Guides

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PENBERTHY SERIES N6 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.
Prior to submitting any claim for warranty service, the owner must submit proof of purchase to Emerson and obtain written
TABLE OF CONTENTS
Product warranty ................................................ 1
1 About the manual .......................................... 2
2 Introduction ................................................2-3
2.1 Features and specifications................... 2
2.2 Design ratings ........................................ 2
2.3 Application data ...................................... 3
3 Inspection and performance confirmation .. 3
3.1 Receiving inspection .............................. 3
3.2 User's rating inspection ......................... 3
4 Installation ..................................................... 4
4.1 Mounting ................................................. 4
4.2 Sight glass installation........................... 4
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 ...............................................4-5
6.1 Preventative maintenance ..................... 5
6.2 Maintenance procedures ....................... 5
7 Removal - disassembly - reassembly ......5-6
7.1 Disassembly ........................................... 5
7.2 Reassembly ............................................ 6
8 Disposal at end of useful life ........................ 6
9 Telephone assistance ................................... 6
10 Exploded parts diagram ................................ 7
Tables and figures
Table 1 Design ratings .................................... 2
Table 2 Tubular glass ratings ......................... 3
Figure 1 Exploded parts diagram .................... 7
authorization to return the product. Thereafter, the product shall be returned to Emerson, with freight paid.
This warranty shall not apply if the product has been disassembled, tampered with, repaired or otherwise altered outside of Emerson's 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 related 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.
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.
valves.emerson.com © 2017 Emerson. All rights reserved. VCIOM-04036-EN 17/05
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PENBERTHY SERIES N6 GAGECOCKS
InstallatIon, operatIon and maIntenance InstructIons
1 ABOUT THE MANUAL
This manual has been prepared as an aid and guide for personnel involved in 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 or compatible for the user's specific application.
WARNING
Failure to follow any instruction could possibly result in a malfunction of the gagecocks, resulting in leakage, severe physical injury or property damage.
2 INTRODUCTION
2.1 Features and specifications
Penberthy Series N6 gagecocks are supplied in pairs (upper and lower) that house each end of a transparent sight glass tube. This gagecock/ glass combination forms a gage that indicates liquid level as well as liquid characteristics accurately. Standard features of Series N6 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, drain cock and handwheel.
Series N6 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 rising ball check and ball inspection plug in the lower gagecock in conjunction with a steam cleaner in the lower gagecock stem. The upper gagecock is equipped with a horizontal ball check and a leaky ball seat formed in the body.
WARNING
Under no circumstances should Series N6 gagecocks be used for steam-water applications unless they are equipped with one of the above optional features. Use of standard Series N6 gagecocks without these features may result in sudden release of pressure, leakage of contained fluid, severe physical injury or property damage.
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.
SAFETY INSTRUCTIONS
Under most circumstances, Series N6 gagecocks are not recommended without the 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.
TABLE 1 - DESIGN RATINGS AT MAXIMUM AND MINIMUM OPERATING TEMPERATURES
Body material Glass packing material Maximum allowable working pressure Maximum steam pressure
Bronze Rubber (standard) 200 psig (1.38 mPa) at -20°F ( -29°C) to + 100°F (38°C)
190 psig (1.31 mPa) at +200°F ( 93°C)
Bronze PTFE (optional) 200 psig (1380 mPa) at -20°F ( -29°C) to + 100°F
125 psig ( 860 mPa) at +400°F (204°C)
NOTE
Pressure/temperature ranges in above table are subject to the limitations of the tubular glass. See Table 2.
125 (825 mPa)
125 (825 mPa)
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PENBERTHY SERIES N6 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 NPS DN 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 (1.97) 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)
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.
3 INSPECTION AND PERFORMANCE CONFIRMATION
3.1 Receiving inspection
On receipt of 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 pressure/temperature rating stamped on nameplate (163) 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 referred to previously.
4. The materials of construction of the gagecocks 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.
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PENBERTHY SERIES N6 GAGECOCKS
InstallatIon, operatIon and maIntenance InstructIons
4 INSTALLATION
Installation should only be undertaken by qualified, experienced personnel who are familiar with this equipment and have read and understood all of the instructions in this manual. The user should refer to relevant technical data sheets or product proposal to obtain dimensional information for the specific size and model of gagecock set.
4.1 Mounting
1. Prior to actual installation, turn handwheel or lever of each gagecock clockwise until stem closes against seat.
2. Mount upper and lower gagecocks to 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 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 glass packing nut, glass packing gland and glass packing, and mount them on sight glass prior to insertion of glass in upper and lower gagecock bodies. See Figure 1 for proper assembly sequences.
4.3 Guard rod installation
Guard rods (two required) are assembled downward through upper gagecock with swaged portion on rods at the top. Bottoms of rods are positioned into respective holes in the lower gagecock.
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 gagecocks 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.
WARNING
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 any instructions could result in severe personal injury or property damage.
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PENBERTHY SERIES N6 GAGECOCKS
InstallatIon, operatIon and maIntenance InstructIons
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 for signs of:
1. Leakage around stem area.
2. Internal stem leakage.
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 'f' of Disassembly and 'a' through 'f' of Reassembly instructions.
2. Signs of an internal stem leak is an indication of a worn or damaged stem or seat.
a. To replace the stem, follow disassembly
steps a through 'f' and reassembly steps 'a' through 'f'.
b. To renew the seat surface, follow
Disassembly steps 'a' through 'f'. Renew seat by using a fine lapping compound and a mandrel with the same size, shape and seat angle as the stem. Flush gagecock body clean and reassemble by following steps 'a' through 'f' of Reassembly.
Note: Series N6 gagecocks have an integral
seat. The gagecock body must be replaced when the 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 'g' through 'l' and Reassembly steps 'a', 'b' and 'g' through 'm'. In the event of improper compression, leakage can be stopped by tightening the gage coupling nut.
4. Signs of internal or external corrosion could be an indication of a misapplication. An investigation should immediately be carried out 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 'g' through 'l' and Reassembly steps 'a', 'b' and 'g' through 'm'.
SAFETY INSTRUCTIONS
New glass packing must be used when replacing glass.
7 REMOVAL - DISASSEMBLY - REASSEMBLY
WARNING
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 any instructions could result in severe personal injury or property damage.
7.1 Disassembly
a. Close upper and lower gagecocks. b. Open draincock and allow gagecocks to
drain.
c. Remove handwheel screw, nameplate and
handwheel or lever from stem.
d. Loosen and remove stem packing nut. e. Remove stem by turning counterclockwise,
along with stem packing and stem packing retainer.
f. Slip the stem packing and stem packing
retainer off the stem.
g. Remove guard rods if present. h. Loosen glass packing nuts on both upper
and lower gagecocks.
i. Slide sight glass upward into upper
gagecock until bottom of tubular glass clears the stuffing box connection on the lower gagecock.
j. 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.
k. Remove sight glass from upper gagecock. l. Remove glass packing nuts, glass packing
glands and glass packing from both the upper and lower gagecocks.
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PENBERTHY SERIES N6 GAGECOCKS
InstallatIon, operatIon and maIntenance InstructIons
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. Slip packing retainer on stem and install
new packing.
d. Thread stem assembly into gagecock by
turning clockwise until stem seats and then back off one turn.
e. Assemble stem packing nut and tighten in
place.
f. Assemble handwheel or lever, nameplate,
and handwheel screw on stem and tighten securely into place.
g. Replace glass packing nut, glass packing
gland and new glass packing on each end of tubular glass.
h. 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.
i. Tighten upper gagecock to original position
holding sight glass in place with upward force to insure its clearing lower sight glass connection. Check vertical alignment of gagecocks.
j. Slide sight glass down into lower gagecock
sight glass connection to a positive stop. k. Tighten glass packing nuts. l. Close both gagecocks by turning handwheel
or lever clockwise until stem seats. m. Replace guard rods.
Refer to Section 5 for operation of gagecock when returned to service.
9 TELEPHONE ASSISTANCE
If you are having difficulty with your SeriesN6 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.
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.
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PENBERTHY SERIES N6 GAGECOCKS
InstallatIon, operatIon and maIntenance InstructIons
10 EXPLODED PARTS DIAGRAM
FIGURE 1
PARTS LIST
Item Description
40 Rod 48 Glass 37 Nut, glass packing 35 Retainer, glass packing 34 Packing, glass 11 Body 15 Ball 17 Stem 18 Retainer, stem packing 25 Packing, stem 26 Nut, stem packing 28 Handwheel 163 Nameplate 100 Screw
RECOMMENDED SPARE PARTS
Item Description Min. qty.
18 Retainer, stem packing 2 25 Packing, stem 2 26 Nut, stem packing 1 34 Packing, glass 2 35 Retainer, glass packing 2 37 Nut, glass packing 1 48 Glass 1
Recommended maximun quantities should provide spare parts for 10% of the gagecocks in service.
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