INSTALLATION, OPERATION & MAINTENANCE MANUAL (IOM)
IOM-1164
12-13
MODEL 1164
BACK PRESSURE / RELIEF REGULATOR
SECTION I
I. DESCRIPTION AND SCOPE
The Model 1164 is a modulating back pressure relief regulator used to control upstream (inlet) pressure. Sizes are
3/4", 1", 1-1/2" and 2" (DN 20, 25, 40 and 50) for side (inlet, fl ow-thru,) and bottom (discharge) connections. With
proper trim utilization the unit is suitable for liquid, gaseous, or steam service. Refer to Technical Bulletin 1164-TB
for design conditions and selection rec om men da tions.
CAUTION
This is not a safety device and must not be substituted for a code approved pressure safety relief valve or a rupture disc.
SECTION II
II. INSTALLATION
1. An inlet block valve should always be installed.
2. If service application is continuous such that
shut down is not readily accomplished, it is rec om mend ed that an inlet block valve, outlet block
valve, and a manual bypass valve be installed.
3. Pipe unions should be installed to allow removal
from piping.
4. An inlet pressure gauge should be located ap prox i mate ly ten pipe diameters upstream and within
sight. An outlet pressure gauge is optional.
5. All installations should include an upstream relief
device if the inlet pressure could exceed the pressure rating of any equipment or the maximum inlet
pressure rating of the unit.
WARNING
The maximum inlet pressure is equal to 1.5 times the
larger number of the stated range spring on the name plate, and is the rec om mend ed “upper op er a tive limit” for
the sens ing diaphragm. Higher press ures could dam age
the di a phragm. (Field hydro static tests fre quent ly de stroy
dia phragms. DO NOT HYDRO STATIC TEST THRU AN IN STALLED UNIT; ISO LATE FROM TEST.)
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. Connect the inlet
pressure to the body side connection(s). Fluid will
relieve out of the bottom connection. The double
inlet con nec tions are for in-line in stal la tion (plug
one side connection if in-line in stal la tion is not
required).
CAUTION
6. Clean the piping of all foreign material including
chips, welding scale, oil, grease and dirt before
installing the regulator. Strainers are rec om mend ed.
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.
CAUTION
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.
9. Regulator may be installed in a vertical or hor i zon tal
pipe. If it is a steam system, assure the piping is
properly trapped and oriented.
10. Regulator may be rotated around the pipe axis
360°. Rec om mend ed po si tions are with spring
SECTION III
III. PRINCIPLE OF OPERATION
1. Movement occurs as pressure variations register
on the diaphragm. The registering pressure is the
inlet, P
opposes diaphragm movement. As inlet pressure
drops, the range spring pushes the diaphragm
down, closing the port; as inlet pressure in creas es,
the di a phragm push es up and the port opens.
or upstream pressure. The range spring
1
chamber ver ti cal upwards, or hor i zon tal. Ori ent
such that the spring chamber vent hole does not
collect rain wa ter or debris.
11. Regulators are not to be direct buried un der ground.
12. For insulated piping systems, recommendation is
to not insulate regulator.
13. Spring Chamber Vent Tap - Option 1164-25: 1/4"
NPT Vent. Leave connection vented to at mo sphere
or pipe to outside or sump (the later if fl uid through
valve is toxic or could present a hazard) de pend ing
on the application and the controlled fl uid.
2. A complete diaphragm failure may cause the valve
to fail closed. A cracked metal diaphragm will leak
fl uid thru the vent hole of the spring chamber, but
will continue to operate.
IV. STARTUP
1. Start with the block valves closed. A bypass valve
may be used to maintain system pressure without
changing the following steps.
2. Relax the range spring by turning the adjusting
screw counterclockwise (CCW) a minimum of
three (3) full rev o lu tions. This reduces the inlet
(upstream) pressure set point.
3. If it is a “hot” piping system, and equipped with a
bypass valve, slowly open the bypass valve to preheat the system piping and to allow slow expansion
of the piping. Assure proper steam trap operation
if installed. Closely monitor inlet (up stream) pressure, via gauge, to assure not over-pressurizing.
NOTE: If no bypass valve is in stalled, extra caution should be used in starting up a cold system;
i.e. do everything slowly.
4. Crack open the inlet (upstream) block valve.
5. Slowly open the outlet (downstream) block valve
ob serv ing the inlet (upstream) pressure gauge.
Determine if the regulator is fl owing. If not, slowly
rotate the regulator adjusting screw coun ter clock wise (CCW) until fl ow be gins.
SECTION IV
7. Observing the inlet (upstream) pressure gauge,
ro tate the adjusting screw clockwise (CW) slowly
until the inlet pres sure begins to rise. Rotate CW
until the desired setpoint is reached.
8. Continue to slowly open the inlet (upstream) block
valve. If the inlet (upstream) pressure exceeds
the desired set point pressure, rotate the adjusting
screw CCW until the pressure decreases.
9. When fl ow is established steady enough that both
the outlet and inlet block valves are fully open, begin
to slowly close the bypass valve if installed.
10. Develop system fl ow to a level near its expected
normal rate, and reset the regulator setpoint by
turning the ad just ing screw CW to increase inlet
pressure, or CCW to reduce inlet pressure.
11. Reduce system fl ow to a minimum level and
ob serve setpoint. Inlet pressure will rise from the
setpoint of Step 9. (Ensure that this rise does not
exceed the stated upper limit of the range spring by
greater than 50%; i.e. 30-80 psig (2.07-5.52 Barg)
range spring, at max i mum fl ow the inlet pres sure
should not ex ceed 1.5 x 80 psig (5.6 Barg), or 120
psig (8.3 Barg). If it does, consult factory.)
6. Continue to slowly open the outlet (downstream)
block valve until fully open.
2
12. Increase fl ow to maximum level if possible. Inlet
(up stream or P
setpoint as necessary at the normal fl ow rate.
) pressure should fall off. Readjust
1
IOM-1164
V. SHUTDOWN
1. On systems with a bypass valve, and where system 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 (upstream) block valve. (When on
bypass, the system pressure must be con stant ly
observed and manually regulated.) Close the outlet
(downstream) block valve.
VI. MAINTENANCE
SECTION V
CAUTION
Do not walk away and leave a bypassed reg u la tor
unattended.
2. If the regulator and system are both to be shut down,
slowly close the inlet (upstream) block valve. Close
the outlet (downstream) valve only if reg u la tor removal is required.
SECTION VI
5. Remove spring chamber (2), range spring (3)
and spring button (4).
WARNING
SYSTEM UN DER PRES SURE. Prior to performing any
maintenance, isolate the reg u la tor from the system and
relieve all pres sure. Failure to do so could result in personal injury.
A. General:
1. Maintenance procedures hereinafter are based
upon re mov al of the regulator from the pipe line
where installed.
2. Owner should refer to owner’s procedures
for re mov al, handling, cleaning and disposal
of non-reusable parts, i.e. asbestos gaskets,
etc.
3. Refer to Figure 1 for basic regulator con struc tion. For a blow-up of the TFE seat trim,
see Figure 2.
WARNING
SPRING UNDER COMPRESSION. Prior to re mov ing
spring chamber, relieve spring com pres sion by back ing
out the ad just ing 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 upwards.
2. Relax range spring (3) by turning adjusting
screw (17) CCW until removed from spring
chamber (2).
3. Draw or embed a match mark between body
casting (1) and spring chamber casting (2)
along fl anged area.
4. Remove all diaphragm fl ange nuts (14) and
bolts (13).
IOM-1164
6. Remove pressure plate (5) and inspect to
ensure no deformation due to over-pres sur iza tion. If deformed, replace.
7. Remove diaphragm (9), diaphragm gasket
(10), and O-ring (11).
8. Clean body (1) and diaphragm fl ange. NOTE:
On valves originally supplied as “special
cleaned”, option 1164-55, main te nance must
include a level of clean li ness equal to Cashco’s
cleaning standard #S-1134. Contact factory
for details.
9. Install new O-ring (11), diaphragm gasket (10),
and di a phragm. Apply a light coat of gasket
sealant.
CAUTION
When reassembling, the spring (7) will be under compression. Center all internal parts be fore plac ing the spring
chamber.
10. Center pressure plate (5) on diaphragm (9).
Place the range spring (3) on to the retainer
hub of the pressure plate (5).
11. Place multi-purpose, high temperature grease
into de pres sion of spring button (4) where adjusting screw bears. Set spring button (4) onto
range spring (3); ensure spring button (4) is
laying fl at.
12. Aligning the match marks, place spring cham ber (2) over the above stacked parts. Apply
pressure (manually) to the spring chamber (2)
from opposite sides to compress the spring
(7), so bolting can be started from opposite
sides. Install all bolts (13) and nuts (14) by
3
Loading...