Cashco 1000 LP User Manual

INSTALLATION, OPERATION & MAINTENANCE MANUAL

Model 1000LP

Reducing Regulator

Blowdown-Drain

Blowdown-Drain

Bypass

SRV

Outlet
@ P2

Supply
@ P1

TR

TR

PI

IOM-1000LP-Basic

MODEL 1000LP - BASIC

PRESSURE REDUCING REGULATOR

SECTION I

I. DESCRIPTION AND SCOPE

The Model 1000LP is a pressure reducing regulator used to control downstream (outlet or P2) pressure to
levels between 1 and 30 psig (0.07-2.06 Barg). Sizes are 1/2", 3/4", and 1" (DN15, 20, and 25).

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

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

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

1000HP-Basic 1000HP-Differential 1000HP-Cryogenic

12-13

SECTION II

II. INSTALLATION

CAUTION A

For welded installations, all internal trim parts,
seals and diaphragm(s) must be removed from
reg u la tor body prior to welding into pipeline. The
heat of fusion welding will dam age non-metallic
parts if not re moved. NOTE: This does not apply
to units equipped with extended pipe nip ples.

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 B

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

Recommended Piping Schematic

For Pressure Reducing Station

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.

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. Ensure regulator is properly
trapped if used in a steam ser vice application.

CAUTION C

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.)

11. Regulators are not to be direct buried under­ground.

10. Basic regulator may be rotated around the pipe
axis 360° , and may be installed in a horizontal
or 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.

III. PRINCIPLE OF OPERATION

1. The Model 1000 is available in two variations:
1000LP (larger diaphragm) for downstream
pres sure control from 1-30 psig (.07-2.1 Barg);
1000HP (small er diaphragm) for down stream
pressure control from 10-300 psig (.69-20.7
Barg), body size dependent.

2. Movement occurs as pressure variations reg­ister on the diaphragm. The registering pres sure
is the outlet, P2, or downstream pressure. The
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.

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

13. Cashco does not recommend fi eld welding on
the cyl in der (inlet) end of the body due to the
pos si bil i ty of warpage.

SECTION III

5. The FTO design also is limited by a minimum
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.

6. The Model 1000 includes an aspiration jet ef­ 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 will reduce
perfor mance.

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

4. Due to the FTO design, there is a limit as to how
low of a downstream (P2 or outlet) pressure level
setting is capable for a given inlet P1 pres sure.
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 (P2 or outlet)
pressure settings for a given up stream (P1 or
inlet) pres sure level.

2

IOM-1000LP-Basic

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.

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.

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.

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.

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. 15-30 psig (1.0-2.1
Barg) range spring, at low fl ow the outlet pres-
sure should not exceed 39 psig (2.7 Barg). If it

does, consult factory.

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 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

A. General:

WARNING 1

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.

SECTION V

CAUTION D

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.

1. Maintenance pro ce dures hereinafter are
based upon removal of the unit from the
pipeline where in stalled.

2. Owner should refer to owner's proce dures
for removal, handling and cleaning of re use­able parts, and disposal of non reuseable
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.

IOM-1000LP-Basic

3

4. Regulators originally supplied as “oxygen
cleaned” (Option-55 ) are assembled using
special gasket sealant, Fluorolube GR-362

1

, or equivalent. Cashco, Inc. rec om mends
following factory cleaning spec ifi cation #S-
1134, or equiv a lent. Con tact factory for
details.

1

Product of Fisher Scientifi c Com pa ny

WARNING 2

SYSTEM UNDER COMPRESSION.
Prior to removing fl ange bolts, relieve spring
compression by backing out the adjusting screw.
Failure to do so may result in fl ying parts that
could cause personal injury.

B. Diaphragm Replacement:

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

2. Remove closing cap (31) if provided. Relax
range spring (27) by turning adjusting screw
(6) CCW until removed from spring chamber
(2).

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).

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 “sticking”. NOTE:
Diaphragm 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
from the rock er arm (14) slot. Lift vertically
for the diaphragm sub-assembly re mov al.

8. Place the pusher plate and 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), or cotter pin (15). Loosen

and remove pressure plate nut (11).

9. Remove pressure plate (3) by lifting.

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

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).

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

quantity 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 fl at side of the pressure
plate (3) rests against the dia phragm (20).

Place the pressure plate (3) over the pusher
plate and stud (13). Install pressure plate
nut (11) onto the stud (13) and tighten. Rec­ om mend ed torque val ues are as follows:

CAUTION E

DO NOT USE FIN GERS TO HOLD DIAPHRAGMS
(20) DURING TIGHT EN ING OF NUT (11). Use two

fl ange bolts (8) to keep multiple di a phragms' (20)
properly aligned with bolt holes while tight en ing the
stud nut (10).

4

IOM-1000LP-Basic