Glass Level Gages 101

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Ashley Foster
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1 Instruments, Valves, and Controls Thank You for Attending Today s Webinar: Glass Level Gages 101 Your Host Mike DeLacluyse President Lesman Instrument Co miked@lesman.com Featured Speaker Rob Bolin Product Manager Jerguson (Clark-Reliance) rbolin@clark-reliance.com Follow the Conversation #LesmanWebinar

2 Level Gage & Valve Maintenance Training

3 Why Use a Gage Glass? When systems fail. seeing is believing Even the most advanced fly-by-wire aircraft in the world have windows, would you fly blind?

4 Why Use a Gage Glass? Level Verification Start-Up Operations Confirmation Upset Condition Plant Emergency Instrument Calibration Safety Valve of Level Measurement

5 Gage Types Reflex Glass Molded Prisms on One Side 1 piece of Glass per gage section Clean Service Higher Pressure Ratings Economical Advantage Silver / Black Indication

6 Reflex Gage Components

7 Gage Types Transparent Glass Glass is Flat, Ground & Polished on both sides 2 pieces of Glass per gage section May add shields Allows User to See Fluid Characteristics Used for Interface Applications

8 Transparent Gage Components

9 Borosilicate Glass Materials Up to 600 F (315 C) Up to 300 WSP Over 300 WSP, Mica Protected Transparent HP Borosilicate Up to 600 F (315 C) Higher Tolerances Aluminosilicate Up to 800 F (426 C)

10 Glass Sizes Industry Std (34mm) Size 1 thru 9 Size Length Typical Visible Range 1 4 1/2'' (115mm) 3 3/4'' (95mm) 2 5 1/2'' (140mm) 4 3/4'' (121mm) 3 6 1/2'' (165mm) 5 3/4'' (146mm) 4 7 1/2'' (190mm) 6 3/4'' (171mm) 5 8 5/8'' (220mm) 7 7/8'' (200mm) 6 9 7/8'' (250mm) 9 1/8'' (232mm) 7 11'' (280mm) 10 1/4'' (260mm) /8'' (320mm) 11 7/8'' (302mm) /8'' (340mm) 12 5/8'' (321mm)

11 Gasket Materials Seal vs. Cushion Gasket Seal Gasket is wetted & must be compatible with the process conditions Cushion Gasket prevents metal-to-glass contact Cushion is IFG-5500 Material as Standard Many Customers Upgrade to Grafoil to Match Seal Gasket This eliminates the potential for errors during repairs

12 Gage Lengths Two methods to vary gage length: Change glass size Add more sections Multiple Sections ALWAYS on one chamber Do not use pipe nipples to join multiple single section gages this will result in failure! (1) Section Gage (3) Section Gage

valves Must be installed horizontal Uses kinetic energy

13 Jerguson Safety Ball Check Valves Also known as: Automatic Shutoff Valve Excess Flow Valve All 90-degree valves Must be installed horizontal Uses kinetic energy of fluid to activate ball check Engage at ~5 psi-differential pressure

Importance of Ball Check Valves In the unlikely event of gasket failure or glass breakage the pressure differential will cause the ball check to seat preventing gas/fluid from further

14 Importance of Ball Check Valves In the unlikely event of gasket failure or glass breakage the pressure differential will cause the ball check to seat preventing gas/fluid from further leakage Minimizes the potential for physical injury, or loss of product Provides a means to isolate the gage from service If properly maintained, a glass gage will provide reliable service.

15 Commissioning Safety Ball Check Valves

cause glass breakage Valves should be periodically inspected

16 Ball Check Valve Operation Partially open valves prevent the ball check from seating Rapid opening of isolation valves can cause glass breakage Valves should be periodically inspected for build up which can prevent the ball check from seating properly

$Gage Inspection Gages should be routinely inspected for signs of wear: Cloudy glass Cracks or fractures Pitted chambers / gasket surface Excessive deterioration or rust Bolts$

17 Gage Inspection Gages should be routinely inspected for signs of wear: Cloudy glass Cracks or fractures Pitted chambers / gasket surface Excessive deterioration or rust Bolts torque is vital in ensuring proper operation of the gage Gage should be isolated and torques inspected periodically Gaskets can relax over a period of time and cause loss of torque

Gage Glass & Mica Shields Mica shields protect transparent gages in

potential catastrophic failures High quality mica enables you to see

determining life of a mica shield Excessive condensate formation

19 Gage Glass & Mica Shields Mica shields protect transparent gages in steam service Glass can become steam etched which can lead to potential catastrophic failures High quality mica enables you to see the fluid more clearly Proper blowdown procedure is critical in determining life of a mica shield Excessive condensate formation results in reduced life of mica shield Steam etching High Quality Mica Low Quality Mica

20 Disassembly Step 1 Isolate gage from service, relieve internal pressure and drain.

21 Step 2 Loosen end bolts first, then work towards the center, alternating from top to bottom and following the sequence for tightening in reverse.

22 Step 3 Removal and disposal of components Never re-use gaskets or glass!

24 Step 4 Clean Chamber

26 Step 5 Thorough Inspection

28 Step 6 Thoroughly inspect chamber gasket surface seating area. Remove any pitting damage, steam cuts, gouges, or scars on a milling machine. The minimum dimension shown in Figure A must be maintained.

Recessed Gasket Surface Provides positive location of the seal gasket during both assembly and field repair Makes it possible to repair a Jerguson gage while it is

29 Recessed Gasket Surface Provides positive location of the seal gasket during both assembly and field repair Makes it possible to repair a Jerguson gage while it is mounted to a vessel Safety feature in the fact that it contains the gasket and helps prevent lateral movement which could lead to a gasket blow-out No Recess Recessed

30 Reflex Gage Assembly Place seal gasket on recessed surface of chamber, and cushion gasket on cover Lay glass prism side up on top of the cover cushion gasket

31 Place chamber on top of reflex glass. Insert U-Bolts around chamber into the holes along the back of the cover, and carefully roll chamber over.! Ensure gasket stays aligned throughout the process!

32 Finger tighten the nuts onto the U-Bolts. Ensure bearing face of nut is against the cover Working from the middle set of nuts alternate outward with torque wrench in 5-ft-lb increments.

over like shown Place seal gasket on recessed surface

33 Transparent Gage Assembly Lay back cover face up on the table and insert T-Bolts into holes Flip the back cover over like shown Place seal gasket on recessed surface of chamber, cushion gasket on recessed surfaces of covers

34 Place transparent glass on the cover Place the chamber on top of the glass Place the second set of glass on top of the chamber Place front cover on top of T-Bolts! Ensure gasket stays aligned throughout the process!

35 Finger tighten the nuts onto the T-Bolts. Ensure bearing face of nut is against the cover Working from the middle set of nuts alternate outward with torque wrench in 5-ftlb increments. You will need to hold a wrench on the hex head for to prevent the nut from spinning.

36 Glass Gage Maintenance

39 LumaStar EPL-100 LED Illuminator Features: Cover up to 4 Sz. 9 Sections with One Illuminator LED s have 10 year nominal life rating Easy clamp-on Installation Maintenance Free No bulb changes No Heat Generation Fits Variety of Gages

40 Safe+View Personnel Protection from glass failure Impact Resistant High Temperature or Caustic Service Fits Jerguson and other gage glasses Field Installable No disassembly required!

41 Questions?

42 Upcoming Webinar: Instruments, Valves, and Controls What topics would you like us to cover? Pressure Temperature Level Flow Combustion Process Valving Industrial Wireless Communications Control Systems Data Acquisition Webinar invitation coming soon

43 Instruments, Valves, and Controls Get Social with Lesman blog.lesman.com LesmanInstrumentCo

Thank You for Attending Today s Webinar. Today s Featured Speaker

Instruments, Valves, and Controls Thank You for Attending Today s Webinar Your Host Mike DeLacluyse President Lesman Instrument Company miked@lesman.com Today s Featured Speaker Mike Unterreiner Senior