Cashco DA5 User Manual

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INSTALLATION, OPERATION & MAINTENANCE MANUAL (IOM)

IOM-DA5

MODEL DA5

DA5 - DIRECT-ACTING, SPRING LOADED

BACK PRESSURE REGULATOR

SECTION I

I. DESCRIPTION AND SCOPE

The Model DA5 is a spring operated back pressure regulator used to control upstream (inlet or P1) pressure. Sizes are 1/2" (DN15), 3/4" (DN20), 1" (DN25), 1 1/4" (DN32), 1 1/2" (DN40), 2" (DN50), 2 1/2" (DN65), 3" (DN80) and 4" (DN100). With proper trim uti li za tion, the unit is suitable for liquid, gaseous, or steam service. The Model DA5 is available in a more common “reverse” ﬂ ow direction arrangement, that is balanced against outlet pressure varia- tions, and a “standard” ﬂ ow direction arrangement that is unbalanced. Refer to Technical Bulletin DA5-TB for design conditions and selection rec om men da tions. (NOTE: This product was formerly iden ti ﬁ ed as a Model D5 or Type V;

a Model DA5, D5 and Type V are one and the same product.)

SECTION II

11/13

II. REFERENCES

Refer to Technical Bulletin DA5-TB and DAG-TB for

tech ni cal speciﬁ cations of a Model DA5 regulator.

SECTION III

III. INSTALLATION

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.

1. Install per direction of ﬂ ow arrow indicated on body, or "IN" and "OUT" markings.

2. Regulator may be rotated around pipe axis 360 degrees. For ease of maintenance, the rec om mend ed position is with the spring chamber (4) upwards. In liquid service it is recommended that the spring cham ber be oriented down wards, and that a cus tom er supplied and installed vent valve be pro vid ed at the external sensing connection to bleed-off trapped gas/air under the diaphragm during initial startup.

3. Provide space below, above, and around reg u la tor for removal of parts during maintenance.

ABBREVIATIONS

CCW – Counter Clockwise CW – Clockwise ITA – Inner Trim Assembly

4. Install block valves and pressure gauges to pro vide means for adjustment, operation, bypass, or removal of the regulator. A pipeline strainer is recommended upstream of inlet port to remove typical pipe line debris from entering valve and damaging internal “soft goods”, primarily the dynamic side seal and V-TFE seat when applied.

5. Upstream Sensing Installation Considerations – Internal or External Sensing: a. The regulator may be installed with internal

or external sensing. Unless otherwise spec i ﬁ ed, the regulator is supplied by the factory with internal sensing. The regulator may be con vert ed in the ﬁ eld to external sensing. (See Section VII maintenance, Part H – Converting Internal/External Sensing.

b. Reference DAG-TB, Table DAG-12 for rec-

om men da tions for applying external pressure sensing.

c. For internal sensing, no external line is re-

quired. For external sensing, use an external control line. The line is connected from the port 1/4" (DN8) NPT on the side of the body di a phragm ﬂ ange (see following schematic) to a pressure tap upstream of the regulator.

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A tubing outside diameter of 0.25 inch is adequate for short sensing lines (less than 4 feet). Use 3/8" tubing or 1/4" schedule 40 pipe for sensing lines of 5 to 50 feet.

d. For condensable vapors (i.e. steam) slope the

external sensing line downward 2 to 5 de grees to inlet piping to prevent water pock ets, which allows the diaphragm chamber to al ways be self draining. The external sensing line may be sloped upward for gas or liquid service; i.e. non-condensibles.

CAUTION

DO NOT HYDROSTATIC TEST THROUGH AN IN STALLED UNIT; ISOLATE REGULATOR FROM TEST. The upper range spring pres sure level on the name plate is the rec om mend ed “upper op er at ing limit” for the sens ing di a phragm. Higher pres sures could cause internal dam age. See Table 2 in DA5-TB for pressure limits of different diaphragm materials.

SECTION IV

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.

Recommended Piping Schematic

For Back Pressure/Relief Station

IV. PRINCIPLE OF OPERATION

1. Movement occurs as pressure variations register on the diaphragm. The registering pressure is the inlet, P1, or upstream pressure. The range spring op pos es di a phragm movement. As inlet pres sure in creas es, the diaphragm pushes the range spring

V. STARTUP

1 Start with the block valves closed.

2. Relax the range spring by turning the ad just ing screw CCW (viewed from above) a minimum of three (3) full rev o lu tions. This reduces the inlet (upstream) pres sure set point.

3. Crack open manual bypass valve. Initially pres sur ize system while simultaneously controlling P1 pressure through manual actuation of bypass valve.

up,lifting the valve plug further off the seat; as inlet pres sure decreases, the range spring pushes the di a phragm down closing the valve plug toward the seat.

2. A complete diaphragm failure will cause the reg u la tor to fail closed and process ﬂ uid will discharge from the spring chamber vent hole.

SECTION V

trap op er a tion if in stalled. Close ly monitor inlet (up stream) pres sure via gauge to ensure not over-pres sur iz ing. NOTE: If no by pass valve is

in stalled, extra cau tion should be used in starting up a cold system; (i.e., do ev ery thing slowly).

5. Open the outlet (downstream) block valve.

6. Slowly open the inlet (upstream) block valve to about 25% open, observing the inlet (upstream) pres sure gauge. Determine if the reg u la tor is ﬂ owing. If not, slowly rotate the regulator ad just ing screw CCW (viewed from above) until ﬂ ow be gins.

CAUTION

Do not walk away and leave a bypassed reg u la tor unattended!

4. 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 ex pan sion of the piping. Ensure proper steam

7. When ﬂ ow is established steady enough that the inlet (upstream) block valve can be fully opened, begin to slowly close the bypass valve if installed.

8. 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 inlet pressure, or CCW to reduce inlet pressure.

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9. Reduce system ﬂ ow to a minimum level and ob- serve pressure set point. Inlet pressure will decrease from the set point of Step 8. The max i mum

SECTION VI

build in inlet pressure on increasing ﬂ ow should not exceed the stated upper limit of the range spring by greater than 30%. If it does, consult factory.

VI. SHUTDOWN

1. Shutoff inlet block valve.

2. Remove range spring compression by turning the adjusting screw CCW to reduce the inlet pressure.

VII. MAINTENANCE

A. General:

1. The regulator may be serviced without re mov ing the regulator from pipeline. The regulator is designed with quick-change trim to simplify maintenance.

2. Record the nameplate information to req ui si tion spare parts for the regulator. The in for ma tion should include: size, KM Product Code, Serial Number.

3. Refer to Section IX for selection of recommended spare parts. Only use original equipment parts sup plied by Cashco/KM for re build ing or re pair ing regulators.

4. Owner should refer to owner's procedures for removal, handling, cleaning and disposal of nonreuseable parts, i.e. gaskets, etc.

NOTE: On regulators originally supplied as

“oxygen clean” – Opt-55, maintenance must include a level of cleanliness equal to Cashco cleaning standard #S-1134.

5. The Inner Trim Assembly (ITA) is re moved and re placed in the body (23) as an as sem blage of parts. The ITA consists of the fol low ing parts:

3. Shutoff the outlet block valve.

4. Relieve the trapped upstream and downstream pres sure.

5. The regulator may now be removed from the pipe line or disassembled for inspection and pre ven ta tive main te nance while in-line.

SECTION VII

Item Dynamic Side No. Seal Type Part Description

7 ......................All ...........................Diaphragm Fastener

(Cap Screw or Locknut)

8 ......................All .......Upper Diaphragm Pressure Plate

9 ......................All ......................................Diaphragm(s)

10 .....................All ..........Lower Diaphragm Pusher Plate

13 .................... All......................... Piston/Guide Bearing√

14 .....................All ......................................... Stem Seals

14.1 ............... All ................................ Upper Stem Seal

14.2 ............... All ................................Middle Stem Seal

14.3 ............... All ..............................Lower Stem Seal√

14.4 ............... All ................Lower Pusher Plate Gasket

20 .....................All ...........................................Valve Plug

27 .....................All ...........................Dynamic Side Seal *

27.1 ...............CP ..................................... TFE Cap Seal

27.2 ...............CP ......................... O-ring Energizer/Seal

27.3 .............. UC .......... U-Cup Seal w/Metal Energizer

27.5 ...............PR ................................. Piston Ring Seal

27.6 ...............PR ................. Piston Ring SST Energizer

28 .....................All ............................................ Seat Disc

29 .....................All ...............................Seat Disc Washer

30 .....................All ......................................Seat Disc Nut

* The Dynamic Side Seal (27) and the Cage Seal (15) are

omitted for the FTC ﬂ ow direction regulator. This is Type NO. See Figure 1.

√ 2-1/2" thru 4" body sizes only.

A detailed view of the dynamic side seal parts is shown in Figure 1 on the next page.

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Figure 1: Dynamic Side Seals

(FTC Flow Direction Only)

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B. Main Valve Disassembly:

NOTE: Valves with “Large Internal Sensing” will not

be equipped with any plug (32,33).

WARNING

SYSTEM UNDER PRESSURE. Prior to per form ing any maintenance, isolate the reg u la tor from the sys tem and relieve all pressure. Failure to do so could result in personal injury.*

* Includes external sensing connection if applicable.

1. Shut down the system in accordance with

15. For metal diaphragm constructions, remove diaphragm gasket (37) from body (23) di a phragm ﬂ ange.

16. Remove body (23) from vise. Solvent clean all removed metal parts.

C. Disassembly of the ITA:

Section VI.

1. Body Sizes 1/2" – 2". (See Figures 3 and 4):

2. Disconnect the external sensing line, if in stalled.

a. Obtain two pieces of square-section

barstock with a 3/8"-7/16" dimension, approximately 2 inches long.

3. Though it is possible to disassemble the regulator while installed in a pipe line, it is rec om mend ed that main te nance be done in a shop when pos si ble. The de scrip tions here af ter will assume shop dis as sem bly. Remove regulator from pipe line.

b. Place plug (20) into a vise using the bars

of a. above, use "ﬂ ats" located on plug (20) to prevent vise jaw marks from direct surface contact with the plug (20). Orient with diaphragms on topside.

c. Sizes 1/2"-1": Remove diaphragm lock nut

(7) by rotating CCW.

4. Place the body (23) in a vise with the spring chamber (4) oriented upwards.

Sizes 1-1/4"-2": Remove diaphragm cap-

screw (7) by rotating CCW.

d. Remove upper diaphragm pressure plate

5. Loosen adjusting screw lock nut (2) and relax range spring (6) forces by turning adjusting screw (1) CCW (viewed from above) until removed from spring chamber (4).

(8).

e. Remove diaphragm(s) (9, 9.1, 9.2, 9.9).

Examine diaphragm(s) to determine wheth er failed; determine if op er at ing conditions are ex ceed ing pressure drop

6. Loosen the diaphragm ﬂ ange bolts (11) and nuts (12) uniformly.

or temperature lim its.

f. For composition diaphragm con struc tion,

remove upper stem seal (14.1).

7. Place matchmarks on body (23) and spring chamber (4) ﬂ anges. Com plete ly remove bolt- ing (11,12) Re move the spring cham ber (4).

g. For metal diaphragm con struc tion, re move

lower pusher plate gasket (14.4).

h. Remove lower diaphragm pusher plate

(10).

8. Remove spring follower (5) and range spring (6).

i. Remove middle stem seal (14.2). j. Remove plug (20) from vise, ro tate end-

for-end, and resecure in vise using same

9. Grasp opposite edges of diaphragm (9) and withdraw the ITA from within the cage (19). Set the ITA aside.

metal bars above.

k. Loosen seat disc nut (30) CCW (viewed

from above) ap prox i mate ly two (2) rev o lu tions.

10. Evenly loosen the cage cap screws (18) in single revolution increments until fully loos ened; remove cage cap screws (18).

l. Remove assembly (20, 27, 28, 29, 30)

from vise. Complete re mov al of seat disc nut (30), seat disc washer (29), and seat disc (28).

11. Pull cage (19) up and out of body.

2. Body Sizes 2-1/2" – 4". (See Figure 2):

12. Remove o-ring cage seal (15).

a. Place seat disc nut (30) into a vise with

the plug (20) oriented ver ti cal ly. DO NOT

13. Remove lower cage gasket (21).

over-tighten nut (30) in vise.

b. Place closed-end hex wrench onto di a-

14. If supplied, remove internal sensing drilled plug (32) using 5/32" (4 mm) Allen key wrench for 1/2" - 2" size regulators. Use 3/16" Allen key wrench for 2 1/2" - 4" size regulators.

phragm locknut (7). Place sock et wrench on hex upper end of plug (20). Loos en diaphragm lock nut (7) while holding plug (20) from ro tat ing by socket wrench.

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Re move di a phragm lock nut (7) after fully loosened and socket wrench is removed.

c. Remove upper diaphragm pressure plate

(8).

d. Remove diaphragm(s) (9, 9.1, 9.2, 9.9).

Examine diaphragm(s) to determine wheth er failed; determine if operating conditions are ex ceed ing pressure drop

or temperature limits. e. Remove upper stem seal (14.1). f. Remove lower diaphragm pusher plate

(10). g. Remove middle stem seal (14.2). h. Remove piston/guide bearing (13) with

dynamic side seal (27) in place. i. Remove lower stem seal (14.3). j. Place socket wrench on upper end of plug

(20) as in Step b. above. Rotate plug (20)

CCW (viewed from above) to loosen seat

disc nut (30). Once nut (30) is loos ened,

re move partial as sem bly (20, 27, 28, 29,

30) from vise. Complete re mov al of seat

disc nut (30), seat disc washer (29) and

seat disc (28).

3. Examine the components (27.1, 27.2, 27.3,

27.5, 27.6) of the dynamic side seal (27) to determine if sig niﬁ cant leak age was oc cur ring. If the dynamic side seal (27) shows signs of signiﬁ cant leakage, de ter mine if op er at ing conditions are ex ceed ing pres sure, pres sure drop, or temperature lim its.

Remove dynamic side seal (27) com po nents

from plug (20) for sizes 1/2" – 2", or from piston/guide bearing (13) for sizes 2-1/2" – 4". Spe cial care should be taken when using “tools” to remove the com po nents to ensure that no scratches are im part ed to any portion of the plug (20) or piston/guide bear ing (13) groove.

below; replace parts that can not be re worked or cleaned.

3. QC Finish & Dimensional Re quire ments: a. Valve plug (20);

1. No major defects on plug's (20) bot tom guide spindle, or at guide area near dynamic seal groove.

b. Cage (19);

1. 16 rms ﬁ nish on cylinder bore. No “ledges” formed due to wear from moving dynamic side seal (27).

2. 16 rms ﬁ nish on its seating surface for tight shutoff.

c. Lower guide bushing (24);

1. 16 rms ﬁ nish on bore.

2. Max 0.015 inch (0.38 mm) clearance be tween valve plug (20) spindle and lower guide bushing (24).

d. Internal sensing drilled plug (32);

1. Ensure that bore is minimum 0.125 inch (3.20 mm). Drill out as required.

e. Piston/Guide Bearing (13)(2-1/2"-4"

only);

1. No defects at guide area near dy nam ic seal groove.

4. Staging Material for Reassembly. a. Inspect and clean parts, as nec es sary,

from the spare parts kit. (See Article VII. A.4. comments concerning cleaning for ox y gen service.)

b. Lay out all the regulator parts and check

against the bill of material.

E. Reassembly of the ITA:

1. Position valve plug (20) with seat disc-end upwards. Place new seat disc (28) into recess of lower end of valve plug (20) properly ori ent ed.

4. Solvent clean all metal parts to be reused.

D. Inspection of Parts:

1. After inspection, remove from the work area and dis card the old “soft goods” parts (i.e. o-rings, di a phragms, seals, etc.). Met al di a phragms should always be replaced. These parts MUST be re placed with fac to ry supplied new parts.

2. Inspect the metal parts that will be reused. The parts should be free of surface con tam i nants, burrs, oxides, and scale. Rework and clean the parts as necessary. Surface con di tions that affect the regulator performance are stated

2. Position seat disc washer (29) next to seat disc (28).

3. Engage seat disc nut (30) to secure washer (29) and seat disc (28) to valve plug (20). Firmly hand-tighten.

4. Body Sizes 1/2" thru 2": a. Using the two square-section metal bar-

stock pieces of VII.C.1.a., clamp the plug (20) into a vise with the plug's (20) spindle pointed upwards.

b. Using a torque wrench, tighten the seat

disc nut (30) to 20-35 ft-lbs. by rotating CW.

c. Remove assembly (20, 28, 29, 30) from

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vise and rotate end-for-end and resecure in vise using same metal bars.

5. Body Sizes 2-1/2" thru 4": a. Orient plug (20) with threaded end up-

wards, place into a vise, grasping the seat disc nut (30); tighten the vise lightly, only enough to "hold" the plug (20) from ro tat ing out of the vise. Caution: Over-tight en ing the vise can distort the seat disc nut (30) and give bad ﬁ nal torque values.

b. Place a torque wrench on the 3/4" hex

upper end of the plug (20); tighten the seat disc nut (30) to 40-60 ft-lbs by ro tat ing CW.

6. Installation of dynamic side seal (27) (See Figure 1): NOTE: Dynamic side seal (27) for

sizes 2-1/2"-4" is located on the pis ton/guide bear ing (13). The dynamic side seal can be in stalled on a work bench without need of a vise.

a. Type CP:

1. Stretch o-ring energizer/seal (27.2) over lower circumference of valve plug (20), taking care not to "cut" o-ring en er giz er/seal (27.4). Using thumbs, work the o-ring en er giz er/ seal (27.4) up and into the groove of the valve plug (20). NOTE: A very

slight amount of ﬂ uid and elas tomer com pat i ble lu bri cant is rec om mend ed as an in stal la tion aid. DO NOT “ROLL”

O-RING.

2. Position TFE cap seal (27.1) ring with rectangular cross-section at low er end of valve plug (20). Stretch cap seal (27.1) over low er end of valve plug (20) us ing thumbs to work the cap seal (27.1) onto the valve plug (20). DO NOT USE A TOOL FOR THIS STEP. Con tin ue pressing cap seal (27.1) up wards to wards the groove until the cap seal (27.1) “snaps” into the groove of the valve plug (20).

b. Type PR:

1. Wrap corrugated metal piston ring en er giz er (27.6) over lower cir cum fer ence groove of valve plug (20). Us ing thumbs work the energizer (27.6) into the valve plug (20) groove.

2. Spread a piston ring seal (27.5) and slide over lower circumference groove of valve plug (20), taking care not to “cut” piston ring seal (27.5). Using thumbs, work the piston ring seal (27.5) into the groove of the valve plug

(20). Repeat this pro ce dure with a second piston ring seal (27.5). Ori ent/ rotate the "splits" in pis ton ring seals (27.5) 180° across from each other.

c. Type UC:

1. Stretch u-cup seal (27.3) over upper cir cum fer ence of valve plug (20), tak ing care not to “cut” u-cup seal (27.3) on the protruding shelf that is part of the valve plug's (20) groove. Ensure that the u-cup seal (27.3) is oriented with the cen ter-open-up wards as shown in Fig ure 1, as the u-cup seal (27.3) depends upon the P1-Inlet Pres sure to pres sure ac ti vate the seal for prop er seal ing ac tion.

d. Type NO:

1. For “FTC” ﬂ ow direction ap pli ca tions, it is not required that a dynamic side seal (27) be installed. (When included with the dy nam ic seal (27), better guid ing of valve plug (20) results.) Type “NO” dynamic seal (27) means NO dynamic seal.

2. The more common “FTO Reverse” ﬂ ow direction always requires a dynamic side seal (27).

7. Place ﬂ uid compatible thread anti-seize, Locktite Corp., "Nickel Anti-Seize", or equal on thread ed por tion of di a phragm cap screw (7), sizes 1-1/4" and 1-1/2"; or, thread ed post por tion of valve plug (20), sizes 1/2" – 1" and 2-1/2" – 4". ( NOTE: Regulators cleaned for

ox y gen ser vice should use Fisher Scientiﬁ c Co., "Fluorolube GR-362", or equal.)

8. Body sizes 2-1/2" thru 4".

a. Place o-ring lower stem seal (14.3) over

upper-end of plug (20) and into groove

in plug (20).

b. Place properly oriented piston/guide bear-

ing (13) over up per-end of plug (20) and into po si tion on plug (20).

c. Place o-ring middle seal (14.2) over up-

per-end of plug (20) and into groove of piston/guide bear ing (13).

9. Body sizes 1/2" thru 2".

Place new o-ring mid dle stem seal (14.2) into

groove of valve plug (20) upper surface.

10. Position lower diaphragm pusher plate (10) on/ over upper end of valve plug (20) properly oriented. For composition diaphragm con struc tion the “tongue and groove” “ridge” should

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be on upper side, “ﬂ at” side down wards. For metal diaphragm construction the “rounded” surface of the lower diaphragm push er plate (10) should be on upper side, “ﬂ at” side down- wards.

11. For composition diaphragm construction, place new o-ring upper stem seal (14.1) on/over upper end of valve plug (20) and into groove of lower diaphragm pusher plate (10).

12. For metal diaphragm construction, place com pat i ble gasket sealant on both sides and place new lower pusher plate gasket (14.4) on/over upper end of valve plug (20) and onto lower diaphragm pusher plate (10). (Gasket sealant is Federal Process Corp. “Gasoila” , or equal.) A Teﬂ on gasket (37) may alternatively be ﬁ tted between diaphragm and ﬂ ange of body.

13. Position new diaphragm(s) (9) on/over upper end of valve plug (20). NOTE: For multiple

diaphragms (9) that include TFE material, the TFE should be on the wetted side; for 3-ply elastomeric TFE diaphragm (9), stackup is TFE-HK-TFE, be gin ning with the low er wetted diaphragm (9) ﬁ rst.

14. Position upper diaphragm pressure plate (8) on/over upper end of valve plug (20) properly oriented. For composition di a phragm con struc tion the "tongue and groove" "ridge" should be on lower side, "ﬂ at" side upwards. For metal diaphragm construction the "round ed" surface of the upper diaphragm pressure plate (8) should be on lower side, "ﬂ at" side upwards.

15. a. Body sizes 1/2" thru 1": Engage di a phragm lock nut (7) to thread ed post por tion of valve plug (20) and torque to 60-70 ft-lbs. by rotating CW.

b. Body Sizes 1-1/4" thru 2": In sert anti-

seize coat ed di a phragm cap screw (7) through stacked parts (8, 9, 10,

14.1, 14.4) and into upper end of valve plug (20). Torque-tight en diaphragm cap screw (7) to 120-130 ft-lbs.

c. Body Sizes 2-1/2" thru 4": En gage di a-

phragm lock nut (7) to threaded post of valve plug (20) and wrench-tight en ﬁ rmly. While restraining valve plug (20) from rotating by torque wrench on upper end 3/4" hex, use another

wrench to tighten di a phragm locknut (7) to a torque of 180 - 200 ft-lbs.

16. This completes assembly of ITA; remove from vise.

F. Main Reassembly:

1. Place body (23) in a vise.

2. Reinstall internal sensing drilled plug (32) with compatible thread sealant.

3. Fit the o-ring cage seal (15) into its body (23) groove for reverse ﬂ ow regulators.

4. For metal diaphragm construction, place seal ant (“Gasoila” or equal) on both sides of diaphragm gasket (37) and position on body (23) diaphragm ﬂ ange.

5. Position properly oriented lower cage gasket (21) onto lower shoulder of cage (19).

6. Insert cage (19) into body (23) recess. Prop er ly align all three cage bolt (18) holes as there is only one cir cum fer en tial location pos si ble for this align ment. Engage all of the cage bolts (18), then evenly screw in the cage bolts in one-half revolution increments, tak ing care

NOT TO “COCK” THE CAGE (19) IN THE BODY. Torque the cage bolts (18) to 13-15

ft-lbs.

7. Dynamic Side Seals: a. Type CP: Position the ITA's valve plug

(20) lower end over and into upper end of cage (19) until the cap seal (27.1) edge touch es the upper lip of the cage (19). While gently ap ply ing force to press the valve plug (20) into the cage (19), si mul ta neous ly use hand thumbs to light ly press the cap seal (27.1) inwards into the groove of the valve plug (20) until the cap seal (27.1) “slips into” the cage (19). DO NOT

USE TOOLS, LU BRI CANT, OR HEAVY FORCE TO ENGAGE THE CAP SEAL (27.1) INTO THE CAGE (19). Do not press

inwards on the cap seal (27.1) too much or the cap seal (27.1) may slide out of its groove.

b. Type PR: Position the ITA's valve plug

(20) lower end over and into upper end of cage (19) until the lower piston ring seal (27.5) touch es the upper lip of the cage (19). While gently applying force to press the valve plug (20) into the cage (19), simultaneously use ﬁ ngers to lightly

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circumferentially press the ﬁ rst (low er) piston ring seal (27.5) inwards into the valve plug (20) groove until the ﬁ rst piston ring seal (27.5) “slips into” the cage (19). Repeat for the second piston ring seal (27.5)

c. Type UC: Position the ITA's valve plug (20)

lower end over and into upper end of cage (19) until the cap seal (27.1) edge touches the upper lip of the cage (19). While gently applying force to press the valve plug (20) into the cage (19), si mul ta neous ly use hand thumbs to lightly press the ucup seal (27.3) inwards into the groove of the valve plug (20) until the u-cup seal (27.3) “slips into” the cage (19). DO NOT

USE TOOLS, LU BRI CANT, OR HEAVY FORCE TO EN GAGE THE U-CUP SEAL (27.3) INTO THE CAGE (19).

d. Type NO: Position the ITA's valve plug

(20) lower end over and into the cage (19), allowing plug (20) to enter fully.

8. For composition diaphragm construction, align diaphragm (9) bolt holes with body (23) di a phragm bolt holes.

9. Place a small amount of heavy grease into the adjusting screw (1) threaded opening of spring chamber (4). Reengage both ad just ing screw (1) and its lock nut (2) with spring chamber (4). Allow end of adjusting screw to protrude into interior approximately 1/2 inch.

formed” – pulled together to remove as much entrapped air as possible and allow formation of a diaphragm (9) convolution. Starting with

the body bolts and nuts (11,12) hand tight ened, “preforming” can be ac com plished by any one of the following tech niques:

a. Apply 30-50 psig pressure to the regula-

tor inlet and the regulator outlet. OR b. Block the valve inlet and outlet and apply

30-50 psig under the di a phragm through

the 1/4" NPT ex ter nal pres sure sens-

ing connection on the valve di a phragm

ﬂ ange. AND c. Leave pressure on through tightening

of bolt ing (11,12).

14. Evenly tighten the body bolting (11,12) in an alternating cross pattern in one revolution increments to the following torque value:

Body Size Torque

in.

1/2"-2"

2 1/2"-4"

(DN)

(15-50)

(65-100)

ft-lb (N-m) 30-35 (41-47) 45-50 (61-69)

If supplied, remove pressure of previous Step

13.

G. Converting Internal/External Sensing:

1. Disassemble the regulator and remove the diaphragm(s) (9) according to Steps 1-12 in Part B – Main Regulator Disassembly.

10. Place range spring (6) centered on upper di a phragm pressure plate (8).

11. Place a dab of heavy grease in the recess of the spring follower (5). Place spring follower on upper end of range spring (6).

12. Aligning matchmarks and bolt holes, place spring chamber (4) over range spring (6). If spring chamber (4) ﬂ ange reaches body (23) ﬂ ange without a gap, remove and lower ad just ing screw (1) deeper into spring chamber (4) cavity another 1/4 inch. Repeat this pro ce dure until the adjusting screw (1) keeps the two ﬂ anges from touch ing by approximately 1/8 inch.

13. Reinstall all ﬂ ange bolts (11) and nuts (12) with nameplate (99) located un der one bolt head. Hand-tighten nuts (12).

NOTE: If a three-ply diaphragm is being used,

it is important that the diaphragm (9) is “pre-

2. To convert from internal to external sensing, remove the drilled pipe plug (32) and install a solid pipe plug. Reverse this step for con vert ing from external to internal sensing.

3. Reassemble the regulator according to Part F – Main Regulator Reassembly.

H. Pressure Testing:

1. If a hydrostatic pressure test is per formed, pressure must be applied uniformly to the spring chamber, inlet and outlet of body.

2. Inboard Leakage Test (Seat + Dy nam ic Seal Leakage). a. Determine test pressure. If upper value

CAUTION

DO NOT HYDROSTATICALLY TEST WITHOUT SPRING CHAMBER PRESSURIZED. NOT ADHERING WILL DO PHYSICAL INTERNALS DAMAGE THAT COULD REN DER THE UNIT INOPERABLE.

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of range spring is less than 55 psig, use test pressure of 5 psig less than upper value of range spring. If upper value of range spring is greater than 55 psig, use test pressure of 50 psig.

b. While applying GN

or air pres sur iza tion

ﬂ uid, turn adjusting screw CCW until valve appears to be closed. Add one additional revolution CCW to adjusting screw.

c. Tube outlet to a beaker of water to ob serve

number of escaping gas bubbles.

4. Excessive leakage will require disassembly,

or GN2, whichever is higher.

b. Soap solution test all external leak points;

plugged connections, diaphragm ﬂ ange, di a phragm bolting and spring chamber vent open ing.

examination of sealing elements, correction of problem, reassembly and retesting. NOTE:

This valve is NOT a bubble-tight shutoff de vice. See DAG-TB, Table DAG-10 for leak age classes.

3. Pressure Containment Test. a. Pressurize inlet and outlet to 1.0 x Upper

Value of Range Spring or 30 psig with air

SECTION VIII

VIII. TROUBLE SHOOTING GUIDE

When trouble shooting this regulator there are many possibilities as to what may be causing problems. Many times, the regulator itself is not defective, but one or more of the accessories may be. Sometimes the pro cess may be causing difﬁ culties.

The key to efﬁ cient trouble shooting is in for ma tion and communication. The customer should try to be as precise as possible in their explanation of the problem, as well as their understanding of the ap pli ca tion and op er at ing con di tions.

It is imperative the following information be provided by the customer:

• Fluid (with ﬂ uid properties)

• Range of ﬂ ow rate

• Range of inlet pressure

• Range of outlet pressure

• Range of ﬂ uid temperature

• Range of ambient temperature

Pressure readings should be taken at every location that pressure plays a role - i.e., regulator inlet (as close as possible to inlet port), regulator outlet (as close as possible to outlet port), etc.

Following are some of the more common com plaints along with possible causes and remedies.

1. Erratic regulation, instability or hunting.

Possible Causes Remedies

A. Sticking of internal parts. A. Remove internals, clean, and if necessary, replace.

B. Load changes are too quick for system. B. Convert to external sensing (if necessary) and install

a needle valve in external sensing line.

C. Oversized regulator. C. Check actual ﬂ ow conditions; resize regulator for

min i mum and maximum ﬂ ow; if necessary, replace with smaller regulator.

2. Erratic regulation, instability or hunting (liquid service).

Possible Causes Remedies

A. Air trapped under diaphragm. A. Install valve on external sensing port and bleed off

air. (Install regulator upside down to help prevent re oc cur rence.)

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3. Upstream pressure too high.

Possible Causes Remedies

A. Debris in trim preventing movement. A. Clean unit of debris.

B. Undersized regulator. B. Check actual ﬂ ow conditions; resize regulator for

min i mum and maximum ﬂ ow; if necessary, replace with larger regulator.

4. Diaphragm continually breaks (steam service regulators).

Possible Causes Remedies

A. Stem seals, which protect ﬂ uorocarbon elastomer in

diaphragm assembly, may have deteriorated.

B. Diaphragm nut may not be torqued to proper

value.

C. Diaphragm too stiff causing it to crack in service. C. Follow proper preforming and air evacuation tech-

5. Diaphragm continually breaks (all regulators).

Possible Causes Remedies

A. Differential pressure across diaphragm may have

exceeded limits.

A. Replace with new seals.

Conﬁ rm torque value in accordance with Section VII,

paragraph E-15.

niques during diaphragm installation in accordance with Section VII, paragraph F-13.

A. Reference limits as recorded in technical bulletin

DA5-TB, as well as where the various pressures are acting.

6. Leakage at diaphragm ﬂ ange.

Possible Causes Remedies

A. Body bolts not torqued high enough. A. Torque to proper value (see Section VII, paragraph

F-14).

7. Leakage across seat or dynamic side seal.

Possible Causes Remedies

A. Contamination (debris) in regulator. A. Remove internals, clean, and if necessary, replace

regulator.

B. Oversized regulator. B. Check actual ﬂ ow conditions; resize regulator for

minimum and maximum ﬂ ow; if necessary, replace with smaller regulator.

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SECTION IX

IX. ORDERING INFORMATION NEW REPLACEMENT UNIT vs PARTS "KIT" FOR FIELD REPAIR

To obtain a quotation or place an order, please retrieve the Serial Number and Product Code that was stamped on the metal name plate and attached to the unit. This information can also be found on the Bill of Material ("BOM"), a parts list that was provided when unit was originally shipped. (Serial Number typically 6 digits). Product Code typical format as follows: (last digit is alpha character that reﬂ ects revision level for the product).

–

NEW REPLACEMENT UNIT:

Contact your local Cashco, Inc., Sales Rep re sen ta tive with the Serial Number and Product code. With this information they can provide a quotation for a new unit including a complete description, price and availability.

CAUTION

Do not attempt to alter the original construction of any unit without assistance and approval from the factory. All purposed changes will require a new name plate with appropriate ratings and new product code to accommodate the recommended part(s) changes.

–

PARTS "KIT" for FIELD REPAIR:

Contact your local Cashco, Inc., Sales Rep re sen ta tive with the Serial Number and Product code. Identify the parts and the quantity required to repair the unit from the "BOM" sheet that was provided when unit was originally shipped.

NOTE: Those part numbers that have a quantity indicated

under "Spare Parts" in column "A” reﬂ ect minimum parts required for inspection and rebuild, - "Soft Goods Kit". Those in column “B” include minimum trim replacement parts needed plus those "Soft Goods" parts from column "A".

If the "BOM" is not available, refer to the crosssectional drawings included in this manual for part identiﬁ cation and selection.

A Local Sales Representative will provide quotation for appropriate Kit Number, Price and Availability.

Item No. Description 7 Diaphragm Cap Screw 13 Piston/Guide Bearing 14 Stem Seals

14.1 Upper Stem Seal

14.2 Middle Stem Seal

14.3 Lower Stem Seal 15 Cage Seal 19 Cage 20 Valve Plug 21 Lower Cage Gasket 24 Lower Guide Bushing 28 Seat Disk 29 Seat Disk Washer 30 Seat Disk Nut

Figure 2: Body Sizes

2-1/2" – 4", Composition Diaphragm

FTO – Reverse Flow Direction

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Figure 3

Metal Diaphragm

FTO – Flow To Open

Item No. Description

1 Adjusting Screw 2 Adjusting Screw Lock Nut 4 Spring Chamber 5 Spring Follower (Button) 6 Range Spring 7 Diaphragm Lock Nut 8 Upper Diaphragm Pressure Plate 9 Diaphragm

9.1 Diaphragm (Material #1)

9.2 Diaphragm (Material #2) 10 Lower Diaphragm Pusher Plate 11 Flange Bolts 12 * Flange Bolting Nuts 14 Stem Seal

14.2 Middle Stem Seal

14.4 Lower Pusher Plate Gasket

Item No. Description 18 Cage Cap Screws 19 Cage 20 Valve Plug 21 Seat Ring 23 Body 24 Lower Guide Bushing 26 Tap Plug (Not Shown) 28 Seat Disc 29 Seat Disc Washer 30 Seat Disc Nut 32 Internal Sensing Plug (External Sensing Only) 33 Internal Sensing Drilled Plug (Internal Sensing Only) 37 Diaphragm Gasket 99 Name Plate (Not Shown) * Not required on 2" CS & SST Body Material.

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Figure 4

Composition Diaphragm

FTO – Flow to Open

Reverse Flow Direction (Most Common)

Item No. Description 1 Adjusting Screw 2 Adjusting Screw Lock Nut 4 Spring Chamber 5 Spring Follower (Button) 6 Range Spring 7 Diaphragm Cap Screw or Diaphragm Lock Nut 8 Upper Diaphragm Pressure Plate 9 Diaphragm

9.1 Diaphragm (Material #1)

9.2 Diaphragm (Material #2)

9.9 Diaphragm TFE Cover 10 Lower Diaphragm Pusher Plate 11 Flange Bolts 12 * Flange Bolting Nuts 14 Stem Seal

14.1 Upper Stem Seal

14.2 Middle Stem Seal 15 Cage Seal 18 Cage Cap Screws

Item No. Description

19 Cage 20 Valve Plug 21 Lower Cage Gasket 23 Body 24 Lower Guide Bushing 26 Tap Plug (Not Shown) 27 Dynamic Side Seal

27.1 TFE Cap Seal

27.2 O-ring Energizer/Seal

27.3 U-cup with Metal Energizer

27.5 Piston Ring Seal

27.6 Piston Ring Energizer 28 Seat Disc 29 Seat Disc Washer 30 Seat Disc Nut 32 Internal Sensing Plug (External Sensing Only) 33 Internal Sensing Drilled Plug (Internal Sensing Only) 99 Nameplate (Not Shown) * Not required on 2" CS & SST Body Material.

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The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they are not to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. We reserve the right to modify or improve the designs or speciﬁ cations of such product at any time without notice. Cashco, Inc. does not assume responsibility for the selection, use or maintenance of any product. Responsibility for proper selection, use and maintenance of any Cashco, Inc. product remains solely with the purchaser.

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Cashco, Inc. P.O. Box 6 Ellsworth, KS 67439-0006 PH (785) 472-4461 Fax. # (785) 472-3539 www.cashco.com email: [email protected]

Printed in U.S.A. DA5-IOM

Cashco GmbH Handwerkerstrasse 15 15366 Hoppegarten, Germany PH +49 3342 4243135 Fax. No. +49 3342 4243136 www.cashco.com Email: [email protected]

Cashco do Brasil, Ltda. Al.Venus, 340 Indaiatuba - Sao Paulo, Brazil PH +55 11 99677 7177 Fax. No. www.cashco.com Email: [email protected]