INSTALLATION, OPERATION & MAINTENANCE MANUAL
IOM-1000HP-
MODEL 1000HP - BASIC
PRESSURE REDUCING REGULATOR
SECTION I
I. DESCRIPTION AND SCOPE
The Model 1000HP is a pressure reducing regulator used to control downstream (outlet or P2) pressure to levels
between 10 and 300 psig (0.7-20.6 Barg). Sizes are 1/2", 3/4", 1", 1-1/4", 1-1/2" and 2" (DN15, 20, 25, 32, 40 and
50).
The unit is designed for liquid, gaseous or steam service with proper trim utilization, and proper jet selection.
Refer to Technical Bulletin 1000HP-TB for sizing, application and selection recommendations.
Installation, operation and maintenance manuals (IOM's) also exist for the following other Model 1000 products:
1000LP-Basic 1000HP-Differential 1000HP-Cryogenic
SECTION II
Basic
12-13
CAUTION
For welded installations, all internal trim parts,
seals and diaphragm(s) must be removed from
regulator body prior to welding into pipeline. The
heat of fusion welding will damage non-metallic
parts if not removed. NOTE: This does not apply
to units equipped with extended pipe nipples.
II. INSTALLATION
1. An inlet block valve should always be installed.
An outlet block valve is recommended.
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 man u al
bypass valve be installed.
3. Pipe unions must be installed to allow removal
from piping. Trim can only be changed by unit
removal from pipeline. If fl anges are utilized, a
lap joint fl ange is required on the inlet end of the
regulator 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
with in sight.
5. All installations should include a downstream relief de vice if the inlet pressure could exceed the
pressure rating of any downstream equip ment or
the maximum outlet pressure rating of the unit.
CAUTION
Installation of adequate overpressure protection
is recommended to protect the regulator from
overpressure and all downstream equipment from
damage in the event of regulator failure.
Recommended Piping Schematic
For Pressure Reducing Station
CAUTION
The maximum outlet pressure listed on the name plate is the “upper operative limit” for the sens ing
di a phragm. High er pres sures could damage the di a phragm. (Field hy dro static tests fre quent ly de stroy
dia phragms. DO NOT HY DRO STAT IC TEST THRU
AN IN STALLED UNIT; ISO LATE FROM TEST.)
6. Clean the pip ing of all foreign material in clud ing
chips, welding scale, oil, grease and dirt before
installing the regulator. Strainers are rec om mended.
7. In placing thread sealant on pipe ends prior to
en gage ment, ensure that excess material is re moved and not allowed to enter the regulator upon
startup.
vertical pipe line. Rec om mend ed po si tion is with
spring cham ber ver ti cal upwards. Orient to pre vent the spring cham ber vent hole from col lect ing
rain wa ter or debris.
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, properly trapped if a steam ser vice
application.
10. Basic regulator may be rotated around the pipe
axis 360°
, and may be installed in a horizontal or
III. PRINCIPLE OF OPERATION
1. The Model 1000 is available in two variations:
1000LP (larger diaphragm) for downstream pressure control from 1-30 psig (0.07-2.06 Barg);
1000HP (small er diaphragm) for down stream
pressure control from 10-300 psig (0.7-20.6
Barg), body size dependent.
2. Movement occurs as pressure variations reg ister
on the diaphragm. The registering pres sure is
the outlet, P
range spring opposes di a phragm move ment. As
out let pressure drops, the range spring push es
the diaph ragm down, opening the port; as outlet
pressure increases, the dia phragm pushes up
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.
, or downstream pressure. The
2
11. Regulators are not to be direct buried under-
12. For insulated piping systems, recommen dation is
13. Cashco does not recommend fi eld welding on the
SECTION III
5. The FTO design also is limited by a minimum
6. The Model 1000 includes an aspiration jet ef-
ground.
to not insulate regulator.
cyl in der (inlet) end of the body due to the pos si bil i ty of warpage.
setting is capable for a given inlet P
pressure.
1
This is a function of the ratio of the port area to
diaphragm area. It is possible for there to be too
high of an inlet pressure for the regulator to close
off against. (Refer to 1000-TB, Tables 9 through
12 for limits.) Reduced ports, Option 1000-12,
allow lower down stream (P
or outlet) pressure
2
settings for a given up stream (P1 or inlet) pres sure
level.
pres sure drop. If the pressure drop is below 5
psid, an Option 1000-17 piston spring should be
utilized to assist open ing the piston.
fect, due to the clearance of the piston from the
body near the outlet. These clear ances vary as
to whether the fl uid is a gas (including steam), a
liquid, or a viscous liquid (requires Option 1000-
27). Jets must be se lec ted to match one of these
three general fl uids. An improper jet selection will
reduce perfor mance.
4. Due to the FTO design, there is a limit as to how
low of a downstream (P
or outlet) pressure level
2
7. A complete diaphragm failure will cause the regulator to fail open.
SECTION IV
IV. STARTUP
1. 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.
2. 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.
2 IOM-1000HP-Basic
3. If it is a “hot” piping system, and equipped with
a bypass valve, slowly open the bypass valve
to pre-heat the system piping and to allow slow
expansion of the piping. Ensure proper steam
trap operation if installed. Closely monitor out let
(downstream) pressure via gauge to ensure not
over-pressurizing. NOTE: If no bypass valve is
installed, extra caution should be used in start ing
up a cold system; i.e. do everything slowly.
4. Crack open the outlet (downstream) block
valve.
5. Slowly open the inlet (upstream) block valve ob serv ing the outlet (downstream) pressure gauge.
Determine if the regulator is fl owing. If not, slowly
rotate the regulator adjusting screw clockwise
(CW) until fl ow begins.
8. 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.
9. 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.
6. Continue to slowly open the inlet (upstream) block
valve until fully open.
7. 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.
SECTION V
V. SHUTDOWN
1. On systems with a bypass valve, and where sys tem pressure is to be maintained as the regulator
is shut down, slowly open the bypass valve while
closing the inlet (up stream) block valve. Fully
close the inlet (up stream) block valve. (When on
bypass, the system pressure must be constantly
observed and manually reg u lat ed.) Close the
outlet (downstream) block valve.
SECTION VI
VI. MAINTENANCE
WARNING
SYSTEM UNDER PRESSURE. Prior to per form ing
any maintenance, isolate the regulator from the
system and relieve all pressure. Failure to do so
could result in personal injury.
A. General:
1. Maintenance pro ce dures hereinafter are
based upon removal of the unit from the
pipeline where in stalled.
10. 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 de creas ing fl ow should not
exceed the stated upper limit of the range spring
by greater than 30%; i.e. 10–40 psig (0.7-2.75
Barg) range spring, at low fl ow the outlet pres sure
should not exceed 52 psig (3.6 Barg). If it does,
consult factory.
CAUTION
Do not walk away and leave a by passed regulator
un at tend ed.
2. If the regulator and system are to both be shut down, slowly close the inlet (upstream) block
valve. Close the outlet (downstream) valve only
if reg u la tor removal is required.
4. Regulators originally supplied as “oxygen
cleaned” (Options 1000-55) are assembled
using special gasket sealant, Fluorolube
GR-362 1, or equivalent. Cashco, Inc. rec om mends following factory cleaning specifi cation #S-1134, or equiv a lent. Con tact
factory for details.
B. Diaphragm Replacement:
1. Securely install the body (1) in a vise with the
spring chamber (2) directed up wards.
WARNING
2. Owner should refer to owner's proce dures for
removal, handling and cleaning of re us able
parts, and disposal of nonreusable parts, i.e.
gaskets, suitable sol vents, etc.
3. If desired, the gaskets may be lubricated with
a light oil pro vid ed it is com pat i ble with the
fl uid.
3 IOM-1000HP-Basic
SYSTEM UNDER COMPRESSION. Prior to re mov ing
fl ange bolts, relieve spring com pres sion by backing
out the adjusting screw. Failure to do so may result
in fl ying parts that could cause personal injury.
2. Remove closing cap (31) if provided. Relax
range spring (27) by turning adjusting screw
(6) CCW until removed from spring chamber
(2).
1
Product of Fisher Scientifi c Company
3. Paint or embed a match mark between body
casting (1) and spring chamber casting (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, for
1/2" – 1-1/4" sizes (DN15-DN32), and as two
sep a rate parts, the “pusher plate (5)” and a
“push er plate stud" (13)” for sizes 1-1/2"
and 2" (DN40 & DN50).
6. Pry up the diaphragm(s) (20) and diaphragm gasket (19) around the perimeter of
the body (1) diaphragm fl ange to ensure
that the diaphragm(s) (20) are not “sticking”.
(Dia phragm gasket (19) is not used with a
com po si tion (soft) diaphragm.)
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, ap prox i mate ly 1/2"-3/4" (12-20 mm).
The push er 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 re mov al.
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 locking 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). (Pusher plate gasket (12) is not
used with a composition (soft) diaph ragm.)
Remove the diaphragm(s) (20).
Diaphragm sub-assembly consists of items (10), (11), (12),
(13), (15), (16) and (20). (Metal diaphragm de sign).
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”.
15. Inspect pressure plate (3) to ensure no
de for ma tion due to over-pressurization. If
de formed, bent, or otherwise distorted, re place.
16. Ensuring that the curved outer rim of the pres sure plate (3) rests against the dia phragm (20)
directly, place the pressure plate (3) over the
pusher plate and stud (13). Place nut (11)
onto the stud (13) and tighten. Rec om
mend ed
torques are as follows:
Body
Size
1/2"
3/4" – 1-1/4"
1-1/2" & 2"
DN15
DN20-DN32
DN40-DN50
Brass Trim
Metal/Comp
Diaphragm
25-30 ft-lbs
35-45 ft-lbs
50-60 ft-lbs
34-41 N-m
47-61 N-m
68-81 N-m
Stainless Trim
Metal
Diaphragm
45-50 ft-lbs.
45-50 ft-lbs.
80-90 ft-lbs.
61-68 N-m
61-68 N-m
108-122 N-m
Comp.
Diaphragm
25-30 ft-lbs.
35-45 ft-lbs.
50-60 ft-lbs.
34-41 N-m
47-61 N-m
68-81 N-m
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).
(DO NOT USE FIN GERS TO HOLD DI A PHRAGMS
(20) DURING TIGHT EN ING OF NUT (11).) Use two
fl ange bolts (8) to keep multiple di a phragms (20) bolt
holes prop er ly aligned while tight en ing the stud nut
(10).
CAUTION
4 IOM-1000HP-Basic
Loading...