Cashco 1000 Cryogenic User Manual

INSTALLATION, OPERATION & MAINTENANCE MANUAL

IOM-1000HP-

MODEL 1000HP - CRYOGENIC

PRESSURE REDUCING REGULATOR

SECTION I

I. DESCRIPTION AND SCOPE

The Model 1000HP-5 and 1000HP-36 are cryogenic pressure reducing regulators used to control down stream
(outlet or P
1-1/2" and 2".

The unit is designed for liquid or gaseous service with proper trim utilization, and proper jet selection.

Refer to Technical Bulletin 1000HP-CRYO-TB for sizing, application and selection recommendations.

Installation, operation and maintenenace manuals (IOM's) exist for the following other Model 1000 products:

1000HP-Basic 1000LP-Basic 1000HP-Differential

) pressure to levels above 10 psig, and up to 300 psig (size dependent). Sizes are 1/2", 3/4", 1",

2

Cryogenic

12-13

II. INSTALLATION

1. An inlet block valve should always be in stalled.

2. If service application is continuous such that
shut down is not readily accomplished, it is rec­ om mended that an inlet block valve, and a manual
bypass valve be in stalled.

3. Pipe unions must be installed to allow re mov al
from piping. Trim can only be changed by unit
removal from pipeline. If fl anges are uti lized, a lap
joint fl ange is required on the inlet end of the valve
to help align bolt holes as the cylinder screws into
place.

4. An outlet pressure gauge should be located ap­ prox i mate ly ten pipe diameters down stream, and
within sight.

5. All installations should include a down stream relief
de vice if the inlet pressure could exceed the pres­sure rating of any downstream equip ment or the
maximum outlet pressure rat ing of the unit.

SECTION II

WARNING

The maximum outlet pressure listed on the name plate is
the "upper operative limit" for the sensing diaphragm.
Higher pressures could damage the diaphragm. (Field
hy dro static tests frequently de stroy dia phragms. DO
NOT HY DRO STAT IC TEST THRU AN INSTALLED UNIT;
ISO LATE FROM TEST.)

6. Clean the piping of all foreign ma te ri al in clud ing
chips, welding scale, oil, grease and dirt before
in stall ing the valve. Strain ers are rec om mended.

CAUTION

Installation of adequate overpressure pro tec tion is recom­mended to pro tect the reg u la tor from over pres sure and
all down stream equip ment from dam age in the event of
regulator failure.

7. In placing thread sealant on pipe ends prior to
en gage ment, ensure that excess material is re­moved and not allowed to enter the regulator upon
startup.

8. Flow Direction: Install so the fl ow direction
match es the arrow cast on the body.

9. For best performance, install in well drained
hor i zon tal pipe. Recommended position is with
spring chamber vertically downwards. Orient to
prevent the spring cham ber vent hole from col­lecting rainwater or debris, and so drain hole can

SECTION III

drip melted condensate as re quired. A purge gas
is recommended for the spring cham ber.

10. Regulators are not to be direct buried under­ground.

11. For insulated piping systems, recommen dation is
to not insulate regulator.

12. Cashco does not recommend fi eld welding on
the cyl in der (inlet) end of the regulator, due to the
possibility of warpage.

III. PRINCIPLE OF OPERATION

1. The Model 1000 is available in two vari a tions:
1000LP (larger diaphragm) for down stream pres­sure control from 1-30 psig; 1000HP (small er dia­phragm) for down stream pressure control from
10-300 psig, body size dependent.

2. Movement occurs as pressure variations reg ister
on the diaphragm. The registering pres sure is the
outlet, P
spring opposes di a phragm move ment. As outlet
pressure drops, the range spring pushes the
diaph ragm up, opening the port; as outlet pres­sure increases, the dia phragm push es down and
the port closes.

3. The Model 1000 includes a rocker arm in its op­ er a tion al mechanism. The rocker arm allows the
regulator to operate fl ow-to-open (FTO), rather
than conventional fl ow-to-close (FTC), which
increases rangeability.

4. Due to the FTO design, there is a limit as to how
low of a downstream (P

, or downstream pressure. The range

2

or outlet) pressure level

2

setting is capable for a given inlet P

pressure.

1

This is a function of the ratio of the port area to
di a phragm area. It is possible for there to be too
high of an inlet pressure for the regulator to close
off against. (Refer to Technical Bulletin, Tables 6
and 7 for limits.) Reduced port, Option -12 allow s
low er down stream (P

or outlet) pressure set tings

2

for a given up stream (P1 or inlet) pressure level.

5. The FTO design also is limited by a minimum
pressure drop. If the regulator pressure drop is
below 5 psi, an Option 1000-17 Piston Spring
should be utilized to assist open ing the valve
piston. (Standard with 1000-5; must be speci fi ed
with 1000-36.)

6. The Model 1000 includes an aspiration jet ef fect,
due to the clearance of the piston from the body
near the regulator's outlet. These clear ances vary
as to whether the fl uid is a gas or a liquid. Jets
must be se lec ted to match one of these two gen­eral fl uids. An improper jet selection will reduce
perfor mance.

7. A complete diaphragm failure will cause the regu­lator to fail open.

2 IOM-1000HP-Cryogenic

SECTION IV

IV. STARTUP

1. Purge the system, including the spring cham ber,
to remove air, moisture, carbon dioxide, etc.

2. Start with the block valves closed. A bypass
valve may be used to maintain outlet pressure
in the downstream system without changing the
fol low ing steps.

3. Relax the range spring by turning the adjusting
screw counterclockwise (CCW) a min i mum of
three (3) full revolutions. This re duces the outlet
(down stream) pres sure set point. NOTE: Ro ta-

tion CW or CCW is as viewed from the ad just ing
screw end, i.e. bottom of valve looking up.

4. If equipped with a bypass valve, slowly open the
bypass valve to cool the system piping and to al­low slow contraction of the piping. Closely monitor
outlet (down stream) pressure via gauge to ensure
not over-pres sur iz ing. NOTE: If no bypass valve

is in stalled, extra caution should be used in start­ing up an am bi ent tem pera ture system; i.e. do
everything slow ly.

5. Crack open the outlet (downstream) block
valve.

6. Slowly open the inlet (upstream) block valve ob­ serv ing the outlet (down stream) pres sure gauge.

Determine if the regulator is fl owing. If not, slowly
rotate the reg u la tor ad just ing screw clockwise
(CW) until fl ow begins.

7. Continue to slowly open the inlet (up stream) block
valve until fully open.

8. Continue to slowly open the outlet (down stream)
block valve, especially when the down stream pip­ing system isn't pres surized. If the outlet (down­stream) pressure exceeds the de sired pres sure,
close the block valve and go to Step 2, then return
to Step 4.

9. When fl ow is established steady enough that the
outlet (downstream) block valve is fully open, be­gin to slowly close the bypass valve if in stalled.

10. Develop system fl ow to a level near its expected
normal rate, and reset the regulator set point by
turning the adjusting screw CW to increase outlet
pressure, or CCW to reduce outlet pres sure.

11. Reduce system fl ow to a minimum level and ob-
serve set point. Outlet pressure will rise from the
set point of Step 9. The maximum rise in outlet
pressure on decreasing fl ow should not exceed
the stated up per limit of the range spring by
greater than 30%; i.e. 10-40 psig range spring, at
low fl ow the outlet pressure should not exceed 52
psig. If it does, consult fac to ry.

V. SHUTDOWN

1. On systems with a bypass valve, and where sys­ tem pressure is to be maintained as the reg u la tor
is shut down, slowly open the by pass valve while
clos ing the inlet (up stream) block valve. Fully
close the inlet (up stream) block valve. (When on
bypass, the system pres sure must be con stant ly
observed and man u al ly reg u lat ed.) Close the
outlet (down stream) block valve.

VI. MAINTENANCE

A. General:

1. Maintenance procedures hereinafter are

based upon removal of the regulator unit
from the pipeline where in stalled.

SECTION V

2. If the regulator and system are to both be shut­ down, slowly close the inlet (upstream) block
valve. Close the outlet (down stream) valve only
if regulator re mov al is required.

CAUTION

Do not walk away and leave a bypassed regulator unat­tended.

SECTION VI

2. Owner should refer to owner's proce dures for

removal, handling and cleaning of re use able
parts, and disposal of non reuseable parts, i.e.
asbestos gaskets, suitable sol vents, etc.

IOM-1000HP-Cryogenic

3

3. If desired, gaskets may be oiled, or coated
with gasket sealant or thread sealing com­ pound, pro vid ed the sealant is compatible
with the fl uid. (See below for "oxygen cleaned"
valves.)

4. Valves originally supplied as "oxygen
cleaned" (Options 1000-55, 1000-5 or 1000-

36) are as sem bled using special gasket
sealant, Fluorolube GR-362
Cashco, Inc. recommends following fac to ry
cleaning spec ifi cation #S-1134, or equiv a lent.
Con tact factory for details.

B. Diaphragm Replacement:

1

, or equivalent.

1. Securely install the body (1) in a vise with the
spring chamber (2) directed upwards.

2. Relax range spring (27) by turning ad just ing
screw (6) CCW until removed from spring
chamber (2).

3. Paint or embed a match mark between body
casting (1) and spring chamber cast ing (2)
along fl anged area.

4. Remove all diaphragm nuts (9) and bolts (8).
Remove nameplate (28).

5. Remove spring chamber (2), range spring
(27) and spring button (4).

NOTE: The text hereafter will refer to "pusher plate and

stud (13)" as a single part, which it is for SST trim.
Brass trim uses a separate "push er plate (5)" and a
"pusher plate stud (13)", both of which are peened
together at initial as sem bly.

6. Pry up the diaphragm(s) (20) and diaph ragm
gasket (19) around the perimeter of the body
(1) diaphragm fl ange to ensure that the
diaphragm(s) (20) are not "stick ing".

7. Remove the diaphragm sub-assembly by
slid ing the pusher plate and stud (13) and
nut (11) in the direction of the regulator's
inlet, approximately 1/2"-3/4". The pusher
plate and stud (13), stud nut (10), and stud
collar (16) should disengage with the rocker
arm (14) slot. Lift vertically for the diaphragm
sub-assembly removal.

Diaphragm sub-assembly consists of items (10), (11), (12),
(13), (15), (16) and (20).

8. Place the pusher plate stud (13) in a sepa rate
vise, gripping the stud (13) on the hex ago nal
cast-in-place edges located on the un der­ neath side of the pusher plate stud. NOTE:

Do not remove the stud nut (10), stud collar
(16) and the location lock ing cotter pin (15).
Loosen and remove nut (11).

9. Remove pressure plate (3) by lifting.

10. Pry loose pusher plate and stud (13) from
diaphragm(s) (20) or from pusher plate gas­ ket (12). Remove the diaphragm(s) (20).

11. Remove pusher plate gasket (12) from push er
plate and stud (13).

12. Clean gasket sealing surface of pusher plate
and stud (13) thoroughly.

13. Install new pusher plate gasket (12), if re­ quired, over pusher plate and stud (13).

14. Install new diaphragm(s) (20) over pusher
plate and stud (13). NOTE: Refer to the quan-

tity of diaphragms (20) incorporated per the
bill of materials listing. Depending on outlet
pressure level, various quantities of metal
diaphragms will be "stacked".

4 IOM-1000HP-Cryogenic