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How to Change a Gauge Protector for a Rubber Cup Diaphragm?

September 16th, 2019 by

The regular maintenance of gauge protectors is crucial to ensure they successfully fulfill their purpose of sensing pressure, smoothly. The purpose of the rubber cups is to sense this pressure and protect sensitive gauge internals from harsh drilling fluids, mud or cement. Regular maintenance of this gauge protector promises a lengthy stress-free service in the field.

 

The gauge protector comes with a rubber cup diaphragm. The rubber cups protect the gauge internals from harsh drilling fluids and senses pressure to transmit it to the gauge. When the rubber cup becomes worn, damaged, or blown, it will need to be replaced.

 

If a diaphragm cup (sometimes called a bladder) wears or blows, it could harm the bourdon tube and/or movement as the drilling fluids can enter the gauge. Inspecting the rubber cup during regularly scheduled maintenance will prolong the life of the gauge.

 

How to Check If The Rubber Diaphragm Needs A Replacement?             

Begin with checking the diaphragm cup’s round end. If there is a small hole in this area, the system will consequently lose fluid and fill with air instead. If the system has been compromised, the rubber cup sides will fill up like a balloon, in turn, allowing the drilling fluids into the system.  When examining the system make sure that the retainer nut is flush with the housing.  If the retainer nut is not flush, the diaphragm cup will display a cut on the lip. If cuts, wear, or tears are found on investigation then it’s time to replace the diaphragm cup.

 

Important Safety Notice

Given that we couldn’t possibly assess every factor or the outcome of the investigation, some warnings against the use of specific service methods stated in these methods /guide can damage the equipment or render them unsafe or could have possible hazardous consequences. Keeping this in mind, we urge you to read further.

 

What You’ll Need

 

1.Needle Nose Pliers

2.Retainer Nut

3.Screwdriver

4.Diaphragm Cup

5.Retainer Nut Wrench

6.Diaphragm Protector

 

Here is a step by step method of how you can replace a rubber diaphragm in gauge protector:

 

Step One: Flip the Unitized Mud Gauge (UMG) on the side with the gauge face down in a vice to expose the base of the flange. The gauge should be placed upside down so that the glass stays protected during the removal of the diaphragm.

 

Step Two: With the help of a 1/2″ ratchet with no socket, place ratchet into the center hole in the bottom of the flange.

 

Step Three: Loosen the retainer nut which holds rubber diaphragm in place by making use of a ratchet then finish off by loosening the nut by hand and removing it.

 

Step Four: Slide a flat-head screwdriver between the rubber diaphragm cup and the diaphragm housing wall. Making use of the screwdriver, pull the rubber cup diaphragm away from the wall of the gauge protector housing.

 

Step Five: On achieving a gap large enough, grab the lower rim of the diaphragm using a pair of needle nose pliers. Pull the diaphragm to remove it. If the diaphragm has ruptured, make sure you replace all the pieces.

 

Step Six: Turn the gauge back on side to expose the center hole. Insert the new rubber cup diaphragm into housing. Ensure you place the closed-in top into the housing first, with the larger rubber cup opening going into housing last. Secure it into the hole until it fits perfectly. The diaphragm will rest in the grove located near the opening and will give a slight pop when back in place.

 

Step Seven: Replace the retainer nut and finger tighten it in place. Grease retainer nut threads and lip with silicon-based grease to keep the retainer nut from cutting or tearing the rubber cup diaphragm.

 

Step Eight: Ensure that the retainer nut is sitting just below the lip of gauge protector housing (below flush). Using a ratchet, tighten retainer nut in place. Make sure you don’t over tighten the retainer. Overtightening retainer nut could potentially reduce gauge accuracy and/or destroy rubber cup diaphragm.

 

To maintain the life of a gauge, regular inspection and the timely replacement of the rubber diaphragm is essential. With regular maintenance, this gauge protector will successfully provide years of worry-free service in the field.

 

   

Diaphragm Valves vs Electrically Actuated Control Valves

May 23rd, 2019 by

What are Diaphragm Valves?

 

Diaphragm valves are named after a flexible disc that is connected with a platform at the top of the valve body, which in turn, forms a seal. A diaphragm is an adaptable component that responds to pressure and engages a force to open, close and control a valve.

 

Diaphragm valves use a durable diaphragm that is connected to the compressor by a stud, which is proceeded by being shaped into the diaphragm. The diaphragm is shoved, making contact with the bottom of the valve body, to shut-off as an alternative, instead of tweaking the liner closed to shut it off. Diaphragm valves are manually operated and are ideal to control the flow control by offering a variable and precise opening for handling pressure drop through the valve. A handwheel is turned until the desired amount of medium flow is transmitted throughout the system. The handwheel is in motion until the compressor pushes the diaphragm to counter the bottom of the valve body to either halt the flow or make way in the bottom until there is a passage for flow.

 

The diaphragm is secured to a compressor by a stud constructed inside the apparatus. The valve stem is moved up to start or enhance the flow in the compressor. To stop or reduce the flow, the compressor is modulated along with the diaphragm being thrust against the foot of the valves. Diaphragm valves are reliable for managing the flow of liquids containing solid matter and have the ability to be fixed in any position.

 

 

What are Electrically Actuated Control Valves?

 

There are two types of electric valve actuators; rotary and linear. Each of them uses special valves to function.

 

The motor varies in voltage and puts a lot of emphasis on torque generation. To avoid heat damage from excessive functions or override current draw, electric actuator motors come along with a sensor which marks an increase in temperature in the motor mechanisms. The sensor gives out a signal when the circuit needs to be opened when overheated. The circuit can be closed again when the motor reaches a moderate temperature.

 

Electric actuators are dependent on a gear train attached directly to the motor to boost the motor speed which navigates the speed of the device. You can change the output speed by installing a cycle length control variable.

 

 

Why are Electrically Actuated Control Valves better?

 

– You do not need an air supply. Air supply may not be available in many places and it is also hard to keep track on.

 

– Colder climates can cause compressed air systems to freeze or clog but the electrically actuated controlled valves have the ability to withstand these temperatures.

 

– They are cost effective.

   

THE IMPORTANT FEATURES AND ROLES OF A ROLLING DIAPHRAGM

March 14th, 2019 by

Diaphragm seals are found in industries that need maximum execution in severe environments, such as the automobile, aviation, pharmaceutical, and food and water-processing industries. Mechanical systems usually use hydraulic actuators which is one of the major factors in the applications. Rolling diaphragms are ductile fluid control tools that are used to secure a perfect seal in any system, involving a piston and cylinder. Made from a combination of elastomer and fabric, they are found inevery shape and size.

 

The bellofram rolling diaphragm is a pliable and durable seal that has a unique layout which allows proportionately long piston strokes while avoiding the sliding friction, throughout. Coming in the shape of a cone that has been cut, or top hat, the diaphragm is folded within itself when positioned so that, during the mechanism, it rolls and rotates repeatedly on the piston skirt and cylinder wall.

 

The rolling action is easy and trouble-free, completely omitting any sliding contact and diverging friction. The exterior flange is clamped to the cylinder in the middle, connected to the top of the piston, this shapes a faultless blockade, averting pressure loss and massive leakage. It all comes down on the substance and outline that has been chosen to function thoroughly with an applied pressure of 3000 pounds. The temperatures range from –120ºF to +600ºF. There are diaphragms that are accessible, with a high tolerance to oil, acids, alkalies, steam and other corrosive fluids.

 

Features of a Rolling Diaphragm

A couple of advantages of rolling diaphragms include precise, repeatable positioning, long stroke lengths, without a spring rate, that refers to pressure made by rubber trying to return to its moulded area.

 

– It is completely friction free.

– There is no breakaway friction or evasion to start the motion all over again, even after being in one position for a long time.

– The spring rate is constant and there is stability in the resistance that is applied for pressure throughout the stroke .

– Because of its high sensitivity, the diaphragm is easily responsiviations in pressure.

– There won’t be any leaks.

– It is so versatile that it can be equipped for a variety of pressures, temperatures, and liquids.

– The position is consistent along with pressures that are similar, despite the direction of the stroke.

 

Role of Diaphragms in Automotive

Air cylinders have piston and rod seal friction which can encounter a jerk at low speeds or pressures. These seals have low durability, which makes it harder to maintain a course without drift. These can be avoided by replacing them with rolling-diaphragm air cylinders, which don’t have dynamic seals that result in wear and tear, friction or leakage. Furthermore, a top-notch seal is attached around the piston that is held back from the sliding motion and in turn, gives a better seal that doesn’t leak and drain the actuator.

   

What Makes Cryogenic Deflashing Method a Cut Above The Rest?

November 16th, 2018 by

Before the final inspection and packing, moulded rubber parts must undergo a finishing process to remove excess flashes. “FLASH” is an excess amount of rubber that oozes out between the two halves of a mould during the moulding of rubber parts.

 

The flash occurs in areas where different sections of the mould join together and are called the ‘parting line flash’. The remaining part of the mould flash traces around where the different sections of the mould join together.

 

Flashes cannot be avoided no matter what technique has been used to manufacture these rubber products. While manufacturing high-performance materials for growing markets like electronics and automotive, intricate finishes, consistency and strict tolerance must be met.

 

Importance of Cryogenic Deflashing

 

 

This is the only method that makes it possible to eradicate complex flash at the inner dimensions. Parts with a thin flash can be removed through cryogenic deflashing quickly. The traditional deflashing methods generally deliver a poor deflashing effect as it is done manually with the help of blades, scissors or knives. The manual trimming method has a high variability in quality and the production rate due to the geometry of the parts. Since the finish quality is not up to the mark, it leads to high rejection rates. Unevenly deflashed products when used can affect and damage the machine it is used in.

 

The Process of Cryogenic Deflashing

 

 

Cryogenic Deflashing is a combination of rapid rotation, nitrogen and plastic blast media is used to get rid of the flash in an extremely precise and economical way. The rubber parts are arranged in a perforated container which is then inserted in a blast enclosure.

 

The containers rotate and evenly expose all sides towards the blast media. The enclosure is insulated with firm polyurethane foam for stable temperatures. The liquid nitrogen decreases the temperature inside and freezes the flashing to make it fragile.

 

With the use of pure nitrogen with zero moisture the requirement of a dryer is eliminated. A fast-moving impeller shoots the polycarbonate pellets in the container. These high-speed pellets trim the inner as well as the outer diameter flashing neatly in a single operation. The effective lubricity and hardness lessens the impeller’s wear and increases its durability.

 

Parting- line flash thickness determines the capability of the system to finish the moulded part in concurrence with the cycle time and LIN consumption. A thicker flash is more difficult to get rid of and requires lengthier deflash cycle time which results in higher LIN consumption. The optimum parting-line flash thickness is 0.001” to 0.005”. Optimum finish quality and LIN consumption are based on the mould design and condition.

 

 

Advantages of Cryogenic Deflashing

 

 

Cryogenic deflashing offers numerous advantages over other traditional or manual deflashing methods:

 

● This process maintains an element of integrity and precision and ensures greater productivity.

● Due to this using a batch process, the cost of per piece is lesser as the number of parts processed in a specific time increases. This makes the manufacturing process economical and cost-efficient.

● Repairing or replacing a mould rises up the expenses bracket. In this method, the moulds can bede-flashed which extends their durability.

● It delivers consistent results in every lot.

● This technique is completely non-abrasive.

● The entire procedure is highly automated which eliminates the need of a human operator.

● This method eradicates the use of any toxic chemicals and is enclosed to a minimum sound which proves it to be environmental-friendly.

 

Harkesh Rubber uses cryogenic deflashing which is the most advanced deflashing process, unlike most of the other OEM’s. This method polishes the parts (typically O-Rings) and minimizes any sign of the flash or parting line delivering an efficient and precise product.

 

With this process, we ensure precision and fulfill our commitment of delivering a quality product. This technique not only improves the performance of the product but also saves the time and effort invested which eventually reduces the cost of production as well.

   

Valve World Expo: The Biggest Valve Industry Affair Under One Roof!

August 1st, 2018 by

The Valve World Expo is the biggest ground to showcase and encounter the experts from the valve industries around the world. It is a one-stop shop that will assemble many great minds and act as a platform to meet proficient valve industrialists who will display their products at a large scale. It is a substantial interactive platform that focuses on individual communication. Valve World Expo brings together valve expertise from the:

 

● Oil, Gas, Petrochemical, and Chemical Industry

● Food Processing Industry

● Marine and Offshore Industry

● Water and Waste Water Management Industry

● Automotive and Machine Construction Industry

● Pharmaceutical Industry

● Power Generation Industry

 

The Valve World Expo is undoubtedly the most prestigious event for anyone who uses valve technology in their business.

 

Harkesh Rubber has been serving the valve needs for all kinds of engineering industries for the past 35 years. Our services employ a combination of well-established product mastery and ingenious engineering. What makes us idiosyncratic are the custom-made solutions we provide with optimum quality service.

 

We, at Harkesh Rubber, are experienced at fulfilling the technical merchandise requirements for multiple industries within strict timelines. With a reputation for excellence around the world, we have served clients in Asia, Europe, the Middle East, the USA and many other countries.

 

We provide expert solutions for:

 

Rubber Diaphragms

 

The Rubber Diaphragm is a multifaceted tool that is used as a sealing agent between two elements. It has a huge demand in industries like power generation, aerospace, chemical and process, and more.

 

O-Rings

 

O-Rings have a variety of purposes in different application areas. They are used to stop the air from passing between the two ends. They are available in various metric and inch standard sizes. O-Rings are commonly used for plumbing purposes, automobile requirements, air-conditioning technology, and more.

 

Seals

 

The seal is used in rotary shaft equipment to keep dust, dirt, oil or any other contaminants out while keeping it lubricated. The sealing element, the metal case, and the spring are what form the oil seal.

 

Gaskets

 

We are well-renowned for the production of custom-made rubber gaskets. They are used to prevent leakage between two articles under compression. These gaskets are made to withstand and handle extreme pressure and wear.

 

Harkesh Rubber is proud to exhibit at Valve World Expo 2018. The event will be held from the 27th-29th November 2018 in Düsseldorf, Germany. Make sure to visit our booth, located at Hall 4 / F22 at the venue!