Manual No.

3112710-07011OM, Rev A1
Operator’s Manual
R

OPERATOR’S MANUAL
K80-3705 Pulsation Dampener PAGE
1

HYDRIL ® K20-7500
PULSATION DAMPENER

Pressure Control Equipment

 Operator’s Manual
R

K20-7500 Pulsation Dampener PAGE

1

K20-7500 Pulsation Dampener

Complete Assembly
Hydril Part No. 3112710-07011

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., Rev A1, June 2005 • All Rights Reserved
 Operator’s Manual
PAGE
2 K20-7500 Pulsation Dampener
PREFACE
Hydril makes no warranties of any kind, expressed or
implied, including any warranty of mechanical fitness
for any particular purpose that the work performed pur-
suant to this manual will be free from defects in work-
manship or material.
Hydril retains for itself all proprietary rights in and to all
designs, engineering details, data and procedures set
forth herein. This manual is intended for the sole use of
Hydril customers and they shall strictly control copying
of same, as this manual and all copies thereof may be
recalled by Hydril at any time.
R
This manual makes recommendations only. The cus-
tomer is at all times responsible for actual disassembly,
inspection, re-assembly and testing of the pulsation
dampener body. The customer is also solely respon-
sible for providing competent and qualified persons;
equipment and facilities to perform such operations; and
for workmanship and safety.
If at any time the customer is unable to understand the
recommendations made in this manual or is unable to
follow those recommendations, they should consult the
nearest Hydril location.
 Operator’s Manual
R

K20-7500 Pulsation Dampener PAGE

3

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

REVISION RECORD

Rev A1: Section 6: Parts List: Change part number for bottom connection kit from 1005446-1 to 3109487-1.
 Operator’s Manual
PAGE
4 K20-7500 Pulsation Dampener
1.0 INSTALLATION
CAUTION: Do not attempt to precharge any K-Series
pulsation dampener prior to mounting the unit into the pump
piping system.
The Hydril K20-7500 Pulsation Dampener should be
mounted in the vertical position (refer to Figure 1-1 for
mounting options) with the mating flange connection at
the bottom. The standard bottom connection for a K20-
7500 is 4 1/16” 10,000 PSI (690 Bar). The discharge
dampener should be mounted as close as possible to the
discharge port of the pump. If possible, it is advantageous
that the dampener be mounted in such a way that the fluid
stream is directed towards the fluid opening.
A. Mounting
1. Install stud bolts in the replaceable bottom plate.
2. Position dampener on gasket and mating flange
so that the space between flange and bottom
connection is totally equal around the circumfer-
ence.
3. Install one lubricated nut on each stud and tighten
one turn at a time until dampener is firmly in
place. Assure that space between dampener and
flange is equal.
4. Cross tighten nuts to the proper torque (520 - 600
lb-ft or 710 - 820 N•m).
B. Precharging (NITROGEN ONLY)
The correct precharge is vital for maximizing efficiency of
the pulsation dampener. Generally, precharge pressure
is based on the average operating pressure of the sys-
tem, but precharge can be affected by other system pa-
rameters; for example. the use of MWD tools. For these
applications, consult qualified Hydril personnel for correct
precharging instructions.
Horizontal Discharge
Dampener
Mounting Flange
Discharge Line Tee Discharge Line
Long Radius Elbow
Pump Discharge Flange
Figure 1-1. Mounting Options
R
Charging Valve Nitrogen Bottle
Charging
Hose Assy.
Figure 1-2. Precharge Hookup
WARNING: ALWAYS PRECHARGE WITH ZERO
PRESSURE ON THE SYSTEM AND ALWAYS
PRECHARGE WITH NITROGEN.
A. General Precharging Instructions
1. The charging valve and pressure gauge are
located under the valve guard and are exposed
by removing the valve guard.
2. Before precharging the dampener make sure all
cover stud nuts are tightened evenly and charg-
ing valve and pressure gauge seal nuts are firmly
seated on the dampener.
3. Precharging is accomplished by connecting one
end of the charging hose assembly to a standard
commercially available NITROGEN bottle and the
other end to the charging valve located at the top
of the pulsation dampener (Refer to Figure 1-3).
4. Precharge from a standard commercially avail-
able nitrogen bottle equipped with a pressure
regulator.
5. For those applications where higher precharge
pressures are required, a gas booster pump is
available; for example, Haskell International Inc.
6. Open bottle regulator valve until recommended
precharge pressure shows on regulator gauge.
7. Slowly open charging valve on dampener. Allow
pressure to increase in the dampener until
dampener pressure gauge reads the specified
Vertical Discharge
Dampener
Mounting Flange
Tee
Pump
Discharge Flange
 Operator’s Manual
R

K20-7500 Pulsation Dampener PAGE

5

Top Hex Nut

Clockwise Counterclockwise
Valve Guard to Close to Open
With Lifting Eye

Pressure Charging Valve

Gauge

Cover Plate

Diaphragm
Diaphragm
Stabilizer

Body

Gasket

Bottom Plate

Figure 1-3. Typical K20-7500 Series Pulsation Dampener

precharge pressure. This process will normally D. Leak Detection

take 5 to 15 minutes. Dampener gauge and
regulator gauge should read the same and be
equal to the specified precharge pressure.
8. Close the charging valve. Then, close the regula-
tor valve at nitrogen bottle. Remove the charging
hose, replace the dust plug in charging valve, and
replace the valve guard.
Apply leak detection fluid at all connections around valve,
pressure gauge, cover, body contact surfaces, and studs.
Observe carefully for bubbles that indicate leaks. If any
indications are found, check system for loose connections
and retighten. Allow the nitrogen gas in the dampener to
come to ambient conditions (approximately one-half hour)
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 60 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.
 Operator’s Manual
R

PAGE
6 K20-7500 Pulsation Dampener

2.0 DISASSEMBLY

A. Disassembly Procedure
Refer to Figure 2-1. damaged.
1. Shut down pumps and remove system pressure h. Inspect bottom plate for excessive pitting,
from dampener. corrosion or wear. If these conditions exist,
2. Remove valve guard. consult your nearest Hydril representative for
3. Open charging valve and bleed off all precharge corrective action.
pressure. CAUTION: System and vessel pres-
sure must be at zero psi before removing charg- B. Cleaning and Inspection Procedure
ing valve and pressure gauge or loosening cover 1. Flush diaphragm body, clean and remove scale
or flange bolts. and other foreign material.
4. Remove charging valve and gauge from cover. 2. Inspect inside of dampener body for excessive
5. Check for system fluid in gauge and valve ports. pitting. Corrosion or wear. If these conditions
6. Loosen all cover stud nuts, but do not remove. exist, consult your nearest Hydril representative.
Make sure the cover plate is not pushing upwards 3. Mild pitting or scaling can be removed with
against nuts. This would indicate that pressure application of light duty emery cloth. Inside of
has not been completely removed from damp- dampener must be free of burrs and debris.
ener.
7. After all pressure is removed from dampener,
remove 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.
Remove 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 dia-
phragm 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
connection.
d. Remove dampener from flange connection.
Set stud nuts and gaskets aside and save for
reinstallation.
e. Remove dirt and debris from bottom plate
opening.
f. Remove socket head cap screws that hold
bottom 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
Operator’s Manual
R

K20-7500 Pulsation Dampener PAGE

7

Valve Guard
With Lifting Eye
Pressure
Gauge Charging Valve

Cover Plate

Diaphragm

Diaphragm
Stabilizer

Body

Bottom Plate

Gasket

Figure 2-1. Typical K20-7500 Series Pulsation Dampener - Disassembly

 Operator’s Manual
PAGE
8 K20-7500 Pulsation Dampener
3.0 ASSEMBLY
All metal surfaces of the cover plate, body, and bottom
plate which come into contact with the diaphragm must
be cleaned carefully before reassembly. Scrape and
wire brush all surfaces and completely remove any for-
eign matter, rust or scale. Refer to Figure 3-1 while
following the procedure below.
A. Bottom Plate Gasket Installation
1. Place bottom plate gasket in groove of bottom
plate.
B. Bottom Plate Installation
1. Insert bottom plate into body taking care not to
pinch gasket and align counter bore holes with
tapped holes in body. Install socket head cap
screws and tighten evenly until bottom plate is
snug against body. Torque cap screws to 725 -
800 lb-ft or 980 - 1080 N•m.
C. Diaphragm Installation
1. Apply a light coat of a general lubricant (castor oil
or equivalent) on diaphragm to aid in installation.
2. Pull up on neck of diaphragm while pushing
diaphragm insert area down.
.3. Take the new diaphragm in the at rest position
and roll one side toward the other forming a crude
football shape. A thin belt or strap may be helpful
in holding this shape.
4. Apply lubricant to the folded diaphragm and insert
it long ways into the body of the dampener as far
as possible ( the diaphragm should go over half
way into the dampener body).
5. Fold the remainder of the diaphragm into the
vessel and allow it to open inside the body.
6. Position the diaphragm within the neck of the
vessel.
D. Stabilizer Installation
1. When stabilizer is used, temporarily install hex
screw into insert.
.2. Break vacuum at neck by pulling diaphragm
slightly away from sealing area.
3. Pull up on hex nut so diaphragm bottom moves
up near neck opening.
4. Re-seat diaphragm neck, remove hex screw, and
install stabilizer.
5. Fold stabilizer with edge down and insert into
diaphragm opening.
6. Assemble stabilizer plate, lock washer, and hex
screw through stabilizer and fasten to diaphragm
by attaching hex screw to threaded insert.
R
7. Tighten securely with socket wrench.
NOTE: Make certain that the neck portion of
the diaphragm and cover plate is clean and
free of any debris, rust, or scale. Coat with a
light lubricant prior to installation of cover
plate to the body.
E. Cover Plate Installation
1. Install cover plate, studs, and lubricated nuts.
Cross tighten by hand or wrench, a few turns at a
time, until cover is firmly seated on the dampener
body. Cross tighten to the appropriate torque
(4430 - 4630 lb-ft or 6060 - 6340 N•m).
F Installation of Charging Valve
1. Clean and inspect the charging valve and O-ring
seal (refer to Figure 3-1). Replace valve if
damaged or worn sufficiently to cause doubt in its
ability to seal either at the O-ring or stem.
2. Install the charging valve using commercially
available thread lubricant.
3. Tighten the lower hex nut on the charging valve
using 50 - 60 lb-ft ( 70 - 80 N•m) torque.
G. Installation of Pressure Gauge
1. Install pressure gauge so that the face is posi-
tioned in such a manner that it will be visible
through the valve guard opening
2. Back thread seal nut on valve and thread valve
into tapped hole
3. Tighten to 20 ± 5 ft-lb or 27 ± 7 N•m torque
4. If the gauge is not facing in the proper direction,
take the following steps:
a. Rotate forward if less than a ½ turn is
required to position gauge in proper direction
b. Rotate backward if the previous step is not
possible until the gauge is positioned in the
proper direction ( ½ turn maximum)
c. After gauge is in position, tighten seal nut to
20 ± 5 lb-ft or 27 ± 7 N•m torque.
H. Pressurize Pulsation Dampener
Use precharge instructions in Section 1. Attach valve
guard, and the pulsation dampener is now ready for
use.
Operator’s Manual
R

K20-7500 Pulsation Dampener PAGE

9

Top Hex
Nut
Valve Guard Lower
Hex Nut
With Lifting Eye
O-Ring Stem

Pressure Charging Valve

Gauge

Cover Plate

Diaphragm
Diaphragm
Stabilizer

Body

Gasket

Bottom Plate

Figure 3-1. Typical K20-7500 Series Pulsation Dampener-Assembly

 Operator’s Manual
R

PAGE
10 K20-7500 Pulsation Dampener

4.0 MAINTENANCE

A. Precharge C. High Precharge Effects

1. When properly installed and pre-charged, the 1. If the pre-charge is TOO HIGH, the diaphragm
K20-7500 pulsation dampener is virtually mainte- insert will rest on the bottom of the dampener,
nance free. closing off the fluid inlet.
2. The vessel should be checked periodically for 2. Until the system pressure exceeds the precharge
proper precharge and leaks. Unless conditions pressure, no dampening will take place.
such as ambient temperature, operating condi- 3. During the time the precharge pressure is nearly
tions, or operating temperatures change, check- equal with the system pressure, the diaphragm
ing every six months should be sufficient. will bounce on and off the inlet opening which
could effect the service life of the diaphragm.
B. Low Precharge Effects
1. If the pre-charge pressure is TOO LOW, the
pulsation dampener will fill with excess fluid, thus
losing some of the working volume of the gas and
reducing dampener efficiency.
2. Additionally, excessive flexing of the diaphragm
may cause premature rubber failure at the neck
or equator of the diaphragm.
 Operator’s Manual
R

K20-7500 Pulsation Dampener PAGE

11

5.0 PRECHARGE ADJUSTMENTS

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

PAGE
12 K20-7500 Pulsation Dampener

6.0 PARTS

6.1 Pulsation Dampener Parts List (See Figure 6-1) PN 3112710-07011

Item
No. Description Part No. Qty.

1 Body 3112711 1
1A Cover Plate 3112715 1
1B Stud Bolt 1900096-18072 12
1C Nut, Hex 1900035-18 12
1D Bottom Plate 3112717 1
1E Cap Screw 1900205-20024 8
1F Gasket 1005212-07 1
1G Charging Valve 1920079-2 1
1H Nameplate 3108946-18 1
1J Drive Screw 1900061-12 4
2 Guard 1005206 1
3 Hex Head Cap Screw 1900047-12010 4
4 Diaphragm, Hydrogenated 1005208-07 1
5 Diaphragm Stabilizer 1005213 1
6 Stabilizer Plate 1005214 1
7 Stabilizer Screw 1005215 1
8 Lock Washer 1900105-20 1
9 Hydril Logo Label 3116004-5 2
10 Pressure Gauge 1900168-6 1
11 Lock Nut 1920007-02 1
12 Caution Tag 3103237 1
13 Drive Screw 1900061-12 4

6.2 Accessories

Charging Hose 192006-03 1

Pressure Control Hardware Kit 3110796-076 1
Bottom Connection Kit 3109487-1 1
Contents of Pressure Control Hardware Kit (one-year recommended spare parts list).
Operator’s Manual
R

K20-7500 Pulsation Dampener PAGE

13

10

11

1G

1B

1C

1A

1H 1J
7

8
12 13
6

1D

1E

1F

Figure 6-1. Typical K20-7500 Series Pulsation Dampener - Cutaway for Part Identification
 Operator’s Manual
R

PAGE
14 K20-7500 Pulsation Dampener

R
 Operator’s Manual
R

OPERATOR’S MANUAL
K80-3705 Pulsation Dampener PAGE
2

Pressure Control Equipment

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