PD Series

Solutions With PERFORMANCE! PD10-5000 | PD10-7500

Instruction, Operating & Maintenance Manual

PD Series Gas Charged Dampener

Drilling, Slurry & Industrial Service

Performance Pulsation Control, Inc | www.performancepulsation.com | [email protected]

3309 Essex Dr. Suite 200, Richardson, Texas 75082 | Phone: 972.699.8600 | Fax: 972.699.8602
PD10-500 IOM/9.8.2015
PREFACE Pg 2

This manual describes operating practices and maintenance procedures applicable to PD10
series pulsation dampeners manufactured by Performance Pulsation Control, Inc. The information
contained herein reflects recommendations based on industry best practices and recognized safety
protocols. This manual is not a standards document. Use of the information and procedures
contained in this manual is voluntary and is to be implemented at the sole discretion and risk of the
user.

Performance Pulsation Control, Inc. makes no warranties, expressed or implied, pertaining to the
accuracy, completeness, or efficacy of recommendations presented in this manual. The user is
at all times responsible for operating and maintaining PD10 pulsation dampeners in a manner
that is safe, conforms to the owner’s established business practices, and is in conformance with
applicable regulations.

If at any time the user is unable to understand the recommendations made in this manual or is
unable to follow those recommendations, they should consult with Performance Pulsation Control,
Inc. at the address, telephone number and fax numbers listed in the footer of this manual.

Performance Pulsation Control, Inc | www.performancepulsation.com | [email protected]

3309 Essex Dr. Suite 200, Richardson, Texas 75082 | Phone: 972.699.8600 | Fax: 972.699.8602
PD10-500 IOM/9.8.2015
 PREFACE Pg 3
All Gas Charged Pulsation Control Equipment are designed to Section VIII Division I of the ASME Pressure Vessel Code.

Model Description Assembly Part Number

NBR HNBR URETHANE

PD10-5000 10 Gallon 5000 psi - ASME PD1050-01011 PD1050-07011 PD1050-09011

*Other certifications are available as shown below:

Model Description Assembly Part Number
NBR HNBR URETHANE

5 Gallon 10000 psi - ABS-CDS PD1075-01011-ABS PD1075-07011-ABS PD1075-09011-ABS

PD10-7500 5 Gallon 7500 psi - DNV- PD1075-01011-DNV PD1075-07011-DNV PD1075-09011-DNV
DRILL(N)
5 Gallon 10000 psi - NR13 PD1075-01011-NR13 PD1075-07011-NR13 PD1075-09011-NR13
Other certifications such as PED with CE stamp & GOST are available at an extra charge.

Dampeners are available with the following Diaphragms:

Volume Part # Temperature Range
Material Continuous Intermittent
10 Gallon
PD10-01 0°F-212°F (-18°C-100°C) 250°F (121°C)
Nitrile (NBR)
10 Gallon
Hydrogenated Nitrile PD10-07 0°F-250°F (-18°C-121°C) 300°F (149°C)
(HNBR)
10 Gallon Urethane PD10-09 0°F-180°F (-18°C-82°C) 220°F (104°C)

10 gallon= 18.9 liters 10000 psi = 659.5bar

Performance Pulsation Control, Inc | www.performancepulsation.com | [email protected]

3309 Essex Dr. Suite 200, Richardson, Texas 75082 | Phone: 972.699.8600 | Fax: 972.699.8602
PD10-500 IOM/9.8.2015
 PARTS: PD10-5000 Pg 4

PART NUMBERS
ITEM # DESCRIPTION
PD10-5000
1 VALVE COVER BOLT PD10-VCB
2 VALVE COVER PD10-VC
3 PRESSURE GAUGE PD1050-PG
4 CHARGING VALVE PD1050-CV
5 WARNING TAG PDWTAG1
6 COVER PLATE with lift lugs PD1050-CP
7 COVER PLATE STUD PD1050-CPS
(12 Req.)
8 COVER PLATE NUT PD1050-CPN
(12 Req.)
9 ADAPTER PLATE SEAL PD10-BPS
10 ADAPTER PLATE PD1050-BP

11 ADAPTER PLATE CAP- PD1050-BPCS

SCREW (8 Req.)
12 CONNECTION STUD (8 PD1050-BPST
Req.)
13 CONNECTION NUT (8 Req.- PD1050-BPN
ship loose)
14 DIAPHRAGM NBR P/N: HNBR URE-
PD10-01 P/N: THANE
PD10-07 P/N:
PD10-09
15 NBR STABILIZER PD10-ST-01
16 STABILIZER PLATE PD10-ST-PLT
17 STABILIZER LOCKWASHER PD10-ST-LW
18 STABILIZER BOLT PD10-ST-BLT

ITEM # DESCRIPTION PART NUMBERS

PD10-5000
14,15,16,17,18 DIAPHRAGM NBR P/N: HNBR P/N: URETHANE P/N:
KIT PD10-01-DK PD10-07-DK PD10-09-

DIAPHRAGM REPAIR KIT NBR P/N: HNBR P/N: URETHANE P/N:

KIT + 3,4,5,9 PD1050-01-RK PD1050-07-RK PD1050-09-RK

*Items 12 & 13 are for 4-1/16” API 5k connection

Performance Pulsation Control, Inc | www.performancepulsation.com | [email protected]

3309 Essex Dr. Suite 200, Richardson, Texas 75082 | Phone: 972.699.8600 | Fax: 972.699.8602
PD10-500 IOM/9.8.2015
 PARTS: PD10-7500 Pg 5

PART NUMBERS
ITEM # DESCRIPTION
PD10-5000
1 VALVE COVER BOLT PD10-VCB
2 VALVE COVER PD10-VC
3 PRESSURE GAUGE PD1050-PG
4 CHARGING VALVE PD1050-CV
5 WARNING TAG PDWTAG1
6 COVER PLATE with lift lugs PD1050-CP
7 COVER PLATE STUD PD1050-CPS
(12 Req.)
8 COVER PLATE NUT PD1050-CPN
(12 Req.)
9 ADAPTER PLATE SEAL PD10-BPS
10 ADAPTER PLATE PD1050-BP

11 ADAPTER PLATE CAP- PD1050-BPCS

SCREW (8 Req.)
12 CONNECTION STUD (8 PD1050-BPST
Req.)
13 CONNECTION NUT (8 Req.- PD1050-BPN
ship loose)
14 DIAPHRAGM NBR P/N: HNBR URE-
PD10-01 P/N: THANE
PD10-07 P/N:
PD10-09
15 NBR STABILIZER PD10-ST-01
16 STABILIZER PLATE PD10-ST-PLT
17 STABILIZER LOCKWASHER PD10-ST-LW
18 STABILIZER BOLT PD10-ST-BLT

ITEM # DESCRIPTION PART NUMBERS

PD10-5000
14,15,16,17,18 DIAPHRAGM NBR P/N: HNBR P/N: URETHANE P/N:
KIT PD10-01-DK PD10-07-DK PD10-09-

DIAPHRAGM REPAIR KIT NBR P/N: HNBR P/N: URETHANE P/N:

KIT + 3,4,5,9 PD1050-01-RK PD1050-07-RK PD1050-09-RK

*Items 12 & 13 are for 4-1/16” API 5k connection

Performance Pulsation Control, Inc | www.performancepulsation.com | [email protected]

3309 Essex Dr. Suite 200, Richardson, Texas 75082 | Phone: 972.699.8600 | Fax: 972.699.8602
PD10-500 IOM/9.8.2015
 INSTALLATION & OPERATION Pg 6

Please read all instructions carefully before proceed- 1.1.7. Install the nuts and tighten using a cross
ing with the installation, operation, and charging of pattern to the proper torque using the table
this equipment. below.

WARNING-SAFETY HAZARD: Do not pre-charge Torque Chart

the dampener until the unit has been securely Unit Bolt UNC Lubricated
mounted in place. Use only nitrogen gas when pre- Size Torque
charging!
in mm ft-lb Newton-
1.1. MOUNTING Meters
1.1.1. The dampener should be mounted as close as PD10- 1.625 41 930 686
possible to the pump for maximum effectiveness. 5000
As a general rule, install the dampener within a PD10- Revise Revise Revise Revise
length not to exceed 10 times the connecting 7500
pipe diameter. Special Note: For PD units equipped with a
1-1/4”-7NC socket head cap screw, the torque for
1.1.2. Mount the dampener vertically, and if possible
that fastener is 1175ft. lbs.
in a position where the fluid stream is directed
towards the opening in the adapter plate.
1.1.3. The fluid connection faces should be thoroughly Torque values are for Performance Pulsation Control’s Xylan® coat-
cleaned and the API ring grooves checked for ed studs and nuts. If using a lubricant, consult lubricant supplier or
uniform sealing surfaces. contact PPC for new torque values.
1.1.4. A new API ring (provided by others) should
be cleaned, checked and coated with a light
coat of lubricant before being installed in the
mounting flange ring groove.
1.1.5. Insert the flange mounting studs into the 8
threaded holes in the bottom of PD unit. All
studs should be seated to assure that they are
properly inserted. There should be less than
0.25” (6 mm) variation in installed height.

WARNING-SAFETY HAZARD: Do not lift anything

other than the dampener with the two lifting ears or
material failure may occur. Prior to lifting, ensure
cover plate is firmly attached.

1.1.6. Install the API ring in the ring groove on the

mating flange. Lower the dampener onto the
mating flange. Ensure the space between the
flange and dampener bottom connection is
equal around the circumference.

Performance Pulsation Control, Inc | www.performancepulsation.com | [email protected]

3309 Essex Dr. Suite 200, Richardson, Texas 75082 | Phone: 972.699.8600 | Fax: 972.699.8602
PD10-500 IOM/9.8.2015
 PRE-CHARGE THE DAMPENER WITH NITROGEN Pg 7

WARNING-SAFETY HAZARD: Dampener Cylinder Charging Guide

must be isolated from the system (Ø PSIG), and 10 Gallon
fluid drained from dampener before pre-charging. Pre-charge Pressure No. Cylinders
Always pre-charge with NITROGEN! Using any
Required
other gas, such as compressed air, may cause
an explosion and/or serious bodily injury to 0-900 PSI 1
personnel. For additional information on nitrogen 900-1500 PSI 2
purity, see 2.1.11-14 1500-1600 PSI 3
For higher pre-charge pressures, a gas booster pump (i.e. Haskell
2.1. GENERAL PRE-CHARGING INSTRUCTIONS
International) should be used.
2.1.1. One of the most important factors in proper
pulsation dampener performance is the pre- 2.1.5. Connect the charging hose assembly to
charge pressure. Normally, the pre-charge the loading valve and the regulator
pressure is based on charging the dampener (provided by others) on the nitrogen
up to 75% of the minimum system operating cylinder.
pressure, to a maximum of 2500 psig (172.4
bar). As a general rule, the ratio of gas to 2.1.6. Slowly open the regulator on the nitrogen
liquid volume, the pre-charge ratio (simply cylinder until the recommended pre-charge
calculated as pre-charge pressure/operat- pressure shows on the gauge.
ing pressure), should fall between 25% and
2.1.7. Prepare the loading valve for nitrogen gas
75% at system operating conditions. Oper-
ating the dampener with a pre-charge ratio charging by turning the 5/8” safety nut
outside of this guideline will have a poten- three full turns. Allow the pressure to build
tially negative effect on the diaphragm life. to the proper pre-charge pressure (this
For more specific charging pressures and in- may take up to 15 minutes). The regulator
structions, contact a Performance Pulsation pressure, the charging hose pressure, and
Control representative. dampener pressure gauge should read
2.1.2. Pre-charging the diaphragm is accomplished the same. Dampener gauge must read the
by using commercially available nitrogen cyl- same as other gauges. If not, then replace
inders. The number of nitrogen cylinders re- dampener gauge. Close the loading valve
quired to pre-charge the diaphragm will de- by turning the safety nut fully clockwise
pend on dampener capacity and pre-charge until it stops. Additional cylinders may be
pressure. The chart that follows is based on required to bring to proper pressure. If
the use of STD. 224 cubic feet, 2200 PSI dry additional cylinders are required repeat
nitrogen cylinders. steps 2.1.5 through 2.1.7 until desired
pressure is obtained.
2.1.3. The loading valve and pressure gauge are
under the valve cover. The valve cover can 2.1.8. Apply soapy water or similar leak detection
be removed by removing the two ½” bolts fluid around the fittings, connections, studs
securing the valve cover to the cover plate. and flange mating areas. Ensure that no
bubbles are forming which would indicate
WARNING: Do not remove Warning Tag from a leak. In the event of a leak, re-tighten the
Pressure Gauge. connections and check again. It is possible
2.1.4. Before pre-charging, ensure that all cover that reinstallation of the gauge or loading
plate nuts are secured and evenly torque valve may be required to stop a leak.
tightened. (Refer to Torque Chart) Ensure
that the loading valve is closed by turn-
ing it fully clockwise until it stops; do not
over-tighten. Remove protective cap from
loading valve.

Performance Pulsation Control, Inc | www.performancepulsation.com | [email protected]

3309 Essex Dr. Suite 200, Richardson, Texas 75082 | Phone: 972.699.8600 | Fax: 972.699.8602
PD10-500 IOM/9.8.2015
 PRE-CHARGE THE DAMPENER WITH NITROGEN Pg 8

WARNING: Failure to retighten the safety nut

the full three turns, or until snug, will result in
nitrogen leaking out of the diaphragm; leading
to improper performance and diaphragm failure.

Performance Pulsation Control recommends

using a reputable nitrogen gas supplier that
can provide written bottle filling procedures and
2.1.9. Once at proper pre-charge pressure, ensure
verfication for nitrogen gas purity. Performance
that the cylinder valve is closed and the
pressure regulator is backed off to zero psi Pulsation Control further recommends that each
to ensure no additional gas will come out of bottle be clearly marked with an appropriate
the cylinder tank. Ensure the dampener’s Compressed Nitrogen Gas Association shoulder
loading valve is closed tightly by turning label. All nitrogen gas bottles should come with
the safety nut clockwise three turns or until a “580” type valve unless you are using a bottle
snug. Slowly bleed the pressure from the with a greater than 3000 psig pressure rating,
charging hose by slightly loosening the which will have a “680” type valve installed.
cylinder connection nut until the cylinder’s
pressure gauge reads zero. This should be
done with caution. Release all pressure in
the line before fully removing the connection.
Remove the charging hose assembly and
install the loading valve protective cap.
2.1.10. Confirm pre-charge pressure on dampener
pressure gauge. Reinstall the valve cover
and securely tighten the ½” bolts to 56 ft-lbs
of torque. Your pulsation dampener is now
ready for operation.

WARNING: Verify that your Nitrogen bottles

contain pure nintrogen (N2) gas.

Performance Pulsation Control offers this

caution since there have been recent
documented reports of both end users and
service providers using bottles to charge their
diaphragms (bladders) containing either all
or up to 30% oxygen. Both incidents led to
catastrophic dampener explosions, resulting in
near miss incidents and potential loss of life.

Performance Pulsation Control, Inc | www.performancepulsation.com | [email protected]

3309 Essex Dr. Suite 200, Richardson, Texas 75082 | Phone: 972.699.8600 | Fax: 972.699.8602
PD10-500 IOM/9.8.2015
 INSTALLATION & OPERATION Pg 9

2.2. CLEANING AND INSPECTION CYCLE 2.3.3. Attach properly rated lifting shakles and
lifting device to lift lugs on cover plate. Loosen
2.2.1. Regularly (at least monthly) inspect the pre-
the cover plate nuts using a crisscross pattern.
charge pressure on the dampener, or any Do not remove the nuts at this time. Attach
time the system is showing excess vibrations. properly rated lifting shackles and lifting
Check pre-charge pressure only against Ø device to lift lugs on cover plate. Using a hoist,
PSIG system pressure. slowly and partially lift the cover plate with the
2.2.2. Before inspection and bringing the system provided lifting lug shakles until the rubber
diaphragm seal has been broken, releasing
pressure down to Ø PSIG, observe the gauge
any possible remaining nitrogen gas.
and ensure it is properly functioning. During
pump operations it should display the same WARNING: Do not remove the nuts completely
pressure and the pump’s pressure gauge. If it until the cover plate has been lifted and it has
reads differently or no pressure at all, then the been proven there is no longer a pre-charge on
gauge needs to be replaced. the system. Re-use of removed diaphragm is not
recommended.
2.2.3 During routine diaphragm replacement,
inspect the interior of the vessel for burrs, WARNING: Re-use of removed diaphragm is not
debris or excess pitting. Mild scale or pitting recommended.
may be removed with the application of a light
emery cloth. If excessive pitting, corrosion or 2.3.4. Remove the cover plate nuts and remove the
wear is found, contact a Performance Pulsation cover plate.
Control representative. If corrosion or wear is 2.3.5. Remove the existing stabilizer bolt, lock
found during inspection, the other pulsation washer, stabilizer plate, and stabilizer. Install
dampeners should also be inspected. Flush a lifting eye into the 1”-8NC hole at the bottom
the shell before the diaphragm is reinstalled. of the diaphragm and remove the existing
diaphragm.
2.3. DIAPHRAGM INSTALLATION 2.3.6. Inspect the dampener bore and diaphragm
CAUTION: First ensure there is no pressure in sealing areas for burrs, nicks, or discontinuities
the unit, either in the diaphragm or the piping that could prevent sealing. Repair as
system. necessary using an emery cloth.
2.3.1. Isolate the pulsation dampener from the 2.3.7. Inspect new diaphragm (refer to parts for
pumping system. Ensure that the system proper diaphragm material) for any damage.
pressure reads Ø PSIG. Ensure the new diaphragm is intact and free
CAUTION: Gauge may be broken so you must of any discontinuities.
ensure all nitrogen gas pressure is removed 2.3.8. Coat the bore area and the diaphragm with a
through the loading valve. light coat of grease to aid in installation.
2.3.2. Remove the valve cover to gain access to 2.3.9. Pull up on the neck of the diaphragm while
the loading valve. Keep hardware for reuse. pushing the steel insert at the bottom down,
Remove the protective cap from the loading elongating the diaphragm. Roll the sides of
valve. Turn the 5/8” safety nut fully counter- the diaphragm to form a football shape, using
clockwise to ensure there is no pre-charge a strap to hold it in this position.
pressure left on the system. Confirm the
pressure is Ø PSIG on the pressure gauge. 2.3.10. Insert the folded diaphragm length-wise into
the dampener. Open it up inside the body of
the vessel. Adjust the neck of the diaphragm
to fit uniformly over the gasket surface of the

Performance Pulsation Control, Inc | www.performancepulsation.com | [email protected]

3309 Essex Dr. Suite 200, Richardson, Texas 75082 | Phone: 972.699.8600 | Fax: 972.699.8602
PD10-500 IOM/9.8.2015
 INSTALLATION & OPERATION Pg 10

2.3.11. Install the diaphragm stabilizer, stabilizer f. Remove socket head cap screws that hold
plate,lock washer and bolt. Tighten the adapter plate in place. Set aside and save.
bolt securely using a socket wrench. g. Remove adapter plate from dampener.
2.3.12. Installation of the cover plate is the Remove gasket and inspect for damage.
Set aside and save if reusable. Replace if
reverse of removal. Exercise care when
damaged. Always use new seal that ships
lowering the cover plate to ensure that
with new adapter if replacing.
the diaphragm is not crushed or folded
h. Inspect adapter plate for excessive pitting,
over on the diaphragm sealing surface.
corrosion or wear. If these conditions exist,
2.3.13. Hand tighten nuts onto each stud. Then consult Performance Pulsation Control Inc. for
tighten in a standard crisscross pattern corrective action.
until tightened per required torque.
2.3.14. Pre-charge the diaphragm in accordance WARNING: All metal surfaces of the adapter plate
with section 2.1 of this manual. which come into contact with the diaphragm must
be cleaned carefully before reassembly. Scrape and
wire brush all surfaces and completely remove any
2.5. ADAPTER PLATE REMOVAL AND foreign matter, rust or scale.
REPLACEMENT
2.5.1 If the adapter plate is to be removed for 2.5.2 Place new adapter plate seal in groove of
replacement or inspection, follow the adapter plate.
procedure below: 2.4.3 Insert adapter plate into body taking care
not to pinch seal and align counter bore holes
CAUTION: First ensure there is no pressure with tapped holes in body. Install socket head
in the unit, either in the diaphragm or the cap screws and tighten evenly until adapter plate
piping system. is snug against body. Torque cap screws (refer
a. Verify cover is attached and all hex
to bolting data on pg. 5 for torque). Use standard
nuts are snug. Lift lugs on cover
crisscross pattern.
plate will be used to remove unit from
connection flange. 2.5.4 Repeat appropriate steps of Section 1.1
b. Attach properly rated lifting shackles for remounting the dampener onto the connection
and lifting device to lift lugs on cover flange.
plate.
c. Ensure lifting device(s) are properly
and safely secured before removing
flange connection hex nuts. Remove
all connecting flange hex nuts at
bottom connection. Set aside for reuse
if not damaged.
d. Carefully remove dampener from
flange connection. Do not damage
studs. Set system ring gasket aside and
save for reinstallation. We recommend
always using a new gasket.
e. Remove dirt and debris from bottom
plate opening.

Performance Pulsation Control, Inc | www.performancepulsation.com | [email protected]

3309 Essex Dr. Suite 200, Richardson, Texas 75082 | Phone: 972.699.8600 | Fax: 972.699.8602
PD10-500 IOM/9.8.2015
 MEASUREMENTS: PD10-5000 Pg 11

A 24-1/8” 612.8 mm
B 28-7/8” 733.5 mm
C 23-1/8” 587.4 mm
Weight 1917 lbs 870 kg

*Connection: 4-1/16” API 5000# RTJ

*Ring Gasket R-39 supplied by others

MEASUREMENTS: PD10-7500

A 24-1/8” 612.8 mm
B 28-7/8” 733.5 mm
C 23-1/8” 587.4 mm
Weight 1917 lbs 870 kg

*Connection: 4-1/16” API 7500# RTJ

*Ring Gasket R-39 supplied by others

Performance Pulsation Control, Inc | www.performancepulsation.com | [email protected]

3309 Essex Dr. Suite 200, Richardson, Texas 75082 | Phone: 972.699.8600 | Fax: 972.699.8602
PD10-500 IOM/9.8.2015
Please contact Performance Pulsation Control for any assistance or questions concerning the
information in this manual. All information contained in this manual is the exclusive property of
Performance Pulsation Control, Inc.

PERFORMANCE PULSATION CONTROL, INC.

PO Box 860396, Plano, TX 75086-0396

3309 Essex Drive, Suite 200
Richardson, TX 75082

Phone: 972.699.8600 │ Fax: 972.699.8602

www.performancepulsation.com
[email protected]

© 2015 Performance Pulsation Control, Inc. All Rights Reserved