INSTALLATION, OPERATION, AND MAINTENANCE INSTRUCTIONS

FOR GLASS-TRAC LEVEL GAUGES

I. RECEIPT AND STORAGE

Upon receipt of gauge, check all components Gauges over 100 lbs. in weight should be supported
carefully for damage incurred in shipping. If damage with brackets to avoid imposing high mechanical
is evident or suspected, do not attempt installation. loads on the connecting valves, and piping, and to
Notify carrier immediately and request damage prevent damage from vibration.
inspection.
Bolt torque is vital to the proper operation of a level
The equipment should be stored indoors until ready gauge because gaskets take compression set under
for installation. initial bolt pressure at assembly. Tightening of nuts
before installation, to proper values (Table 1) and in
The user should confirm:
the sequence specified (Figure 1) is necessary to
1. That the gauge model and pressure temperature assure pressure retaining capability of a steam-water
rating stamped on nameplate conforms to the gauge to specific design ratings.
description on the user’s purchase order.
Note: The following procedure is to be done on only
2. That the operating conditions described in the one side of the gauge.
purchase order agree with the actual operating
Using a torque wrench, tighten nuts in five foot-pound
conditions at the installation site.
increments, following the sequence in Figure 1.
Level Gauges should be stored indoors, in a dry
location, until ready to install.
II. INSTALLATION
Installation 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.
Quest-Tec recommends that all level gauge Table 1 : Torque Values
installations be provided with gauge valve sets Gage Model Ft/lbs Nm
designed for the specific service. Ball checks are not
recommended in steam service, but are strongly RL, TL 20 27
recommended for service wherein the contents of the
vessel are flammable. An additional set of straight- RM, TM 32 43
through blocking valves should be installed between RH, TH 40 54
the gauge valves and the vessel.
The gauge should be mounted and connected so that
it does not support the piping weight. Piping not
properly supported, independent of the gauge, may
subject gages to stresses that can cause leaks or
glass breakage.
High mechanical loads may be imposed on a gauge
by the expansion or contraction of pipes due to
temperature fluctuation. Such mechanical loads on
the gauge can be minimized by the use of an
expansion loop and/or a tie bar or bridle.

Note: This document should be reviewed in its entirety prior to installation of equipment.
III. OPERATION: angle will aid in detecting some of these conditions,
which will glisten more brightly than the surrounding
Assure that all installation procedures have been
glass when reflecting light. Detection of any such
completed.
problem areas or any surface wear is sufficient
Check to determine that all connections are pressure evidence of damage. Immediately take the gauge out
tight. of service. Do not proceed with operation of gauge until
glass has been replaced.
Assure that nuts have been re-torqued to their proper
values as specified in Table 1. Shields
Inspect to be sure that glass is clean and free of any Mica Shields which show any signs of clouding, wear,
damage such as cracks, scratches, pits, and chips. or deterioration are an indication that the gauge glass
has been exposed, or could soon become exposed to
Gauges should be brought into service slowly. To
the contained fluid. Immediately take gauge out of
avoid excessive thermal shock or mechanical stress
service. Do not proceed with operation of gauge until
on the glass or chambers, the connecting valves
shields and glass have been replaced.
must open slightly, and the gage temperature and
pressure allowed to slowly equalize with the vessel. Gaskets
If the gauge is equipped with valves which have a A gauge which leaks at the gasket must be immediately
ball check, the valves must be opened all the way taken out of service. Do not proceed with operation of
after pressure and temperature have equalized to gauge until glass, gaskets, and cushions have been
permit operation of the ball check in the event of replaced.
gauge failure. Valves equipped with automatic ball
Connections
checks may cause misreading of the gage where the
liquid level fluctuates rapidly causing the ball checks A gauge which leaks at the connections should be
to accidentally seat. taken out of service, and its connections should be
remade using a good grade of high temperature pipe
IV. MAINTENANCE
sealant.
Maintenance should only be undertaken by qualified
Removal
experienced personnel who are familiar with this
equipment and have read and understood all the Do not attempt to remove the gauge from connecting
instructions in this manual. piping, unless the gage has been relieved of all
pressure, has been allowed to reach ambient
During system shutdown, the gauge valves should be
temperature, and has been drained of all fluid.
left open to permit the gage to lose pressure and cool
with the rest of the system. Failure to leave the Disassembly
valves open during system shutdown will trap high
1. Lay gauge on bench.
pressure fluid in the gauge.
2. Hold gauge firmly, and loosen nuts starting at both
The user must determine upon evaluation of his or
ends of each section and then proceeding from
her own operating experience an appropriate
both ends to the center of each section (reverse
maintenance schedule necessary for the specific
order of Figure 1).
application. Realistic maintenance schedules can
only be determined with full knowledge of the 3. Remove nuts and any washers.
services and application situation involved.
4. Tap covers with rubber hammer as needed to
Maintenance Inspection loosen, and remove.
Glass 5. Remove cushions, glass, shields (if used), and
gaskets.
Regular and careful attention must be given to the
cleaning and inspection of glass. Glass that is etched 6. Tap chamber or remaining covers as necessary
or even slightly scratched is weakened and may with rubber hammer to break loose, and remove
break under pressure. remaining components.
Cleaning of Glass 7. All removed glass, cushions, gaskets, and shields
must be disposed of, and under no circumstances
Keep glass clean using a commercial glass cleaner.
should be re-used and installed on a gauge.
DO NOT use wire brushes, metal scraper, or any
device which could scratch the glass. 8. Clean the glass seating surfaces on the chamber
and cover with a soft metal scraper (preferably
Inspect the surface of the glass for any signs of
brass). Make sure that all burrs, rust, and bits of old
clouding, etching, scratching or deep physical
gasket are removed.
damage such as bruises, checks, or corrosion that
extends through the outer surface of the glass into 9. Extreme care must be taken to avoid gouging or
the interior. Shining a light at approximately a 45° scoring seating surfaces. Failure to properly clean
 gasket surfaces may result in gasket leaks and Transparent Reassembly
high stress points which may cause glass
1. Clean threads on cap screws, and nuts to remove
breakage.
all paint, rust, and scale. Apply a light coat of oil to
Reflex Reassembly threads.
1. Clean threads U-bolts, and nuts to remove all paint, 2. Insert cap screw through bottom cover and lay out
rust, and scale. Apply a light coat of oil to threads. covers on bench, side by side, with the chamber.
Use chamber to space covers and line them up
2. Place the U-Bolts, under the chamber with vision
with vision slots.
slot up.
3. Install one cushion, one glass, one shield (if used)
3. Install one sealing gasket, one glass, and one
and finally sealing gasket inside the cover. (Note:
cushion over the vision slot. Verify that the molded
HQ Mica shields are often supplied in one or more
prism side of the glass is facing down towards the
pieces. The thicker of two pieces should be
chamber vision slot.
placed on the process side.)
4. Carefully work the gauge cover onto the U-bolts,
4. Carefully work the gauge chamber onto the cap
being sure to keep the gasket/glass/cushion stack
screws, being sure to keep the cushion/glass/
in position.
shield/gasket stack in position.
5. Install nuts. Using a torque wrench, tighten nuts in
5. Place gasket, shield, glass and cushion on to the
five foot-pound increments, following the sequence
remaining vision slot.
in Figure 1 until the torque value Table 1 for the
specific gauge is reached. 6. Install cover in place being careful to maintain
components aligned inside.
6. Carefully inspect the vision slots on the
reassembled gauge to verify that the gaskets have 7. Install nuts. Using a torque wrench, tighten nuts in
remained in position. five foot-pound increments, following the
sequence in Figure 1 until the torque value shown
in Table 1 for the specific gauge is reached.

7
7 Item Part
1 Chamber 5
5 2 Gasket
3 Glass 4
4 4 Cushion
6
5 Cover
6
6 Bolt 3
7 Nut
3
2
2
1
1

REFLEX CROSS SECTION TRANSPARENT CROSS SECTION

Quest-Tec Solutions Inc.

13960 South Wayside ● Houston, TX 77048 ● USA
Tel: +1 (281) 240-0440 ● +1 (281) 240-2440 ●
[email protected] www.questtecsolutions.com