Installation, maintenance and operation manual for level water gauges type 9020 and 9030
5
Functional description:
a) Fluid level indicators with reflection glasses (Fig.1).
The reflection glass of the fluid level refracts the
incident rays of lights coming from one side in such a
way that these rays are absorbed by the fluid zone to a
varying degree depending on the index of refraction of
the fluid. As a result, the space filled by the liquid
appears to be dark. In steam or gas zone the light rays
are totally reflected, thus the space not filled with fluid
remains bright. In order to obtain this effect the
reflection glasses on the side facing the fluid is provided
with grooves.
b) Fluid level indicators with transparent glasses (Fig.2).
The function of this type of indicator is based on the fact
that different media (two – steam/water) have different
transparency properties.
As for the transparent level indicator the two media are
placed in between two (or more) transparent glasses –
surrounded by metal a metal casing. Two improve the
visual indication a back-light in form of an illuminator is
used. As the light hits the surface of separation, the
rays will be totally reflected down to the observer, Fig.1. Reflex level gauge
indicating the level very clearly.
The glasses are made of borosilicate glass and, for
safety reasons, should not be subject to pressures
above 35 bars at temperatures above 243oC.
All level gauges are supplied with two cocks – one at the
top and one at the bottom of the level gauge. The
purposes of these are connection to/isolating of the
gauge from the tank or boiler. A third auxiliary valve is
placed on the bottom cock for drainage purposes.
The cocks can be delivery with an automatic safety ball.
The purpose of the safety ball is to prevent the
discharge of vapours, gasses and fluids in the event of
glass breakage during operations.
Fig. 2 Transparent level gauge
Rev. 1.5 9/9-2009
edition 1.
Installation and commissioning:
The level gauges are delivered according to the
customers specifications. Thus, if the distance between
your connections (centre-to-centre distance of
connection flanges) is commensurate with those of the
level gauge, the gauge can be installed. A maximum
deviation of +/- 4mm is acceptable. Be sure to avoid
any tilting or mounting stress on the level gauge.
Before applying media to the level gauge acknowledge
that the bolts of the mounting flanges are properly
tightened and the sealing area is provided with a
gasket, and the union nuts on the connection pieces of
the gauge is firmly tightened onto the cocks.
First open the bottom one of the level gauge cocks
which are still completely closed and then open the top
one. When the fluid column in the level gauge is clearly
found to have settled and stabilized, close the top and
bottom cocks again to prevent any fluid from escaping
in case of glass breakage. To put the gauge into
operation gradually open the bottom and the top cock.
After commissioning, recheck the cover bolts for tight
fit. The sealing and pads of the glass take some time to
settle so that retightening of the bolts will become
necessary – this should also be done as a routine
maintenance check during normal
operation/service. Use the method as described
under “Glasses – use and care”.
Check the blots at least two or three times after putting
the gauge into operation. We recommend the interval of
such inspection to be 24 hours.
Maintenance:
An in-service cleaning of the level gauge glass can be
done by periodical blowing-through. To do so, shut the
lower gauge cock then briefly blow through the upper
gauge cock by opening the drain cock. Ensure that
steam is discharging through the drain cock. Close the
upper gauge cock. Open the lower gauge cock. Ensure
that water (and steam) is discharging through the drain
cock. Open the upper gauge cock and close the drain
cock. Make sure the water level is rising in the gauge
after closure of the drain cock. Repeat this procedure if
necessary. Do not flush through with steam for a longer
period of time. If the level gauge is severely dirty, the
level gauge glass must be dismounted and cleaned.
After dismounting and cleaning, recommission the level
gauge as described above.
Tear/wear/damages caused by blow-through cleaning of
the gauges are not covered by the normal warranty.
We reserve the right for changes
Installation, maintenance and operation manual for level water gauges type 9020 and 9030 edition 1.5
Glasses - use and care: Third step: tightening by use of torque
You should always consult the manufacturer’s wrench with the exact required torque.
instructions before disassembling/assembling/changing Fig. 4. Sequence
sight and gauges glasses. 4) Never grip the gauge body in a vice during
The basic fittings and flanges must satisfy the normal reassembly, but put it on a plane surface.
requirements for working under demanded temperature 9 8 5
5) Never use adhesive or hermetic mastics.
and pressure conditions. It is particular important that Remember that all surfaces must be perfectly
the flatness and freedom of distortion of the sealing clean.
surfaces can be guaranteed.
5 4 3
Parts:
We recommend never to reuse glasses or sealing
materials that has already been exposed to process
conditions and/or is damaged. Use new gaskets which
1
1 2
are flat and undamaged – as well as use glasses which
are not chipped, pitted or any other damaged. Use only
the correct/original parts.

Assembly: 3 6 2 ITEM DESCRIPTION MATERIAL

The flatness should be checked after the sealing 1 CLIP CARBON STEEL #25
surfaces have been thoroughly and completely cleaned. 2 PHILLIPS SCREW STEEL
During assembly the glass must always be centred in 4 3 GASKET GRAPHITE
the fitting in order to avoid a glass-metal contact. The 7 10 4 U-PROFILE CARBON STEEL #25
correct sequence must always be observed (see fig. 4) 5 V-PROFILE CARBON STEEL #25

and the correct torque must be applied to the mounting 6 GASKET GRAPHITE

bolts (see fig. 3) 7 GLASS BOROSILICATE GLASS DIN 7081

Transparent Reflex 8 PIPE CONNECTION 1Cr18Ni9Ti

During operation processes never try to clean the 9 BODY CARBON STEEL #45
10 BOLT STEEL
glasses by mechanical means, never tighten up the nut
and bolt of the fitting and never perform work on the
Dismantling:
1) Close the cocks and remove the level gauge
fitting. When cleaning the glasses only use commercially
body from the cocks.
available cleaning agents. Never use metal scrapers, or
2) Loosen and take out the tightening bolts and
other sharp-edged items, which could scratch the glass
remove all component pieces as well.
and make it unusable – soft brush-like tools are to be
3) Clean the sealing surfaces (see description
preferred.
under “Glasses – use and care”) of the centre
piece and the cushion surface of the cover
Transport packing is used for spare glasses to protect
plates very carefully making sure that they
the glasses. Please leave the glass in the packing until
are clear of any remnants of joints.
they are required for use and avoid contact with other
4) Smear the threads with a thin layer of
glass or metal components.
graphitized grease.
Sight glass condition checks should be carried out
regularly; when used in new and unknown processes Reassembly: ITE M D E SC R IPT IO N M A TE R I A L

daily. Keep maintenance records and replace the 1) Check flatness of sealing surfaces / damaged 1 BO LT ST EEL
2 F R O N T ( BA C K ) P LAT E C AR BO N ST E E L 2 5 #

glasses on a regularly basis. Look for damage, scratches surfaces 3 GASK ET G R A P H IT E

and loss of substance. 2) Fit in the new glasses with new joints. 4 G LA S S B O R O S IL IC A T E G LA S S D IN 7 0 8 1
5 GASK ET G R A P H IT E
3) Reassemble all the other components in the 6 BO D Y C AR BO N ST E E L 4 5 #

Fig. 3. Recommended torques right sequence and tighten the bolts according 7 P IP E C O N N E C T IO N 1 C r1 8 N i9 T i
8 NUT ST EEL
to Fig. 3. and according to the description
Type Recommended torque under “sequence” Fig. 4.
Note: when tightening the bolts, it is
Reflex 45 Nm
recommendable to do this in 3 steps:
Transparent 50 Nm
First step: the nuts and bolts are tightened
gently and evenly (by use of hand),
Second step: tightening by use of torque
wrench with half the required torque.

Rev. 1.5 9/9-2009 We reserve the right for changes