The Model HP-1+6+S is a heavy duty, high pressure differential reducing regulator used to control
differential pressure between downstream outlet (P2)
pressure and a loading (P
chamber. This unit applies to Cashco drawing nos.
32911 (Non-NACE construction), 32909 (CS NACE
construction), or 32907 (SST NACE construction).
Sizes are 1/2", 3/4", and 1-1/2" (DN15, 20, and 40).
) pressure to the spring
LOAD
This unit is most commonly applied to develop a constant differential pressure across a rotating shaft seal
to provide proper sealing and lubricating conditions
over varying pressure ranges. Refer to Tech ni cal
Bulletin HP-S-DIFF-TB for design con di tions and
se lec tion rec om men da tions.
CAUTION A
NOT FOR STEAM SERVICE. NOT FOR OXYGEN SERVICE.
SECTION II
II. INSTALLATION
This unit was designed and is used almost exclusively on compressor and turbo ex pand er seal gas systems. REFER
TO COM PRES SOR / EX PAND ER MAN U FAC TUR ER'S MAN U AL FOR DETAILED IN STAL LA TION, START-UP
AND SHUTDOWN OF THIS UNIT. Install regulator in ac cor dance with direction of fl ow arrow cast on body (1).
CAUTION
Option-1+6 contains single di a phragm con struc tion. In
the event of diaphragm fail ure, the process fl u id will mix
with the load ing fl uid. Please alert your rep re sen ta tive so
an al ter na tive product can be se lect 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.
III. PRINCIPLE OF OPERATION
1. The HP-1+6+S is used to main tain a con stant
differential pressure across the seals of a
com pres sor/expander. A dif fer en tial pres sure re duc ing reg u la tor senses the down stream or outlet
(P2) pres sure on the lower side of the diaphragm
and is opposed by the force of the range spring
plus an ad di tion al loading (P
nect ed to the spring cham ber. The loading (P
pres sure plus the range spring (14) setting (P
equals the outlet (P2) pres sure of the reg u la tor.
The range spring setting (P
setting.
) pressure con-
LOAD
) is the differential
SET
CAUTION
SECTION III
)
LOAD
)
SET
HP-1+6+S
DIFFERENTIAL SCHEMATIC
2. A complete diaphragm failure will cause the reg u la tor to fail open.
Limit any fi eld hydrostatic test to 1-1/2 times the Maximum
Outlet and Spring Chamber Pressure Rat ing (See Ta ble
2 in HP-S-DIFF TB). En sure that the test pressure is applied uni form ly to the body inlet, body outlet, and spring
chamber.
CAUTION B
SECTION IV
IV. STARTUP
REFER TO THE COMPRESSOR / EXPANDER MANUFACTURER'S MANUAL FOR DETAILED START-UP OF
THIS UNIT.
* NOTE: Systems sequencing operations at startup,
normal operation, failure mode(s), and shutdown must
assure that the pressure (P
) on the spring chamber
Load
does not exceed the pressure registering on the wetted
side of the diaphragm. Should this "pressure reversal" occur, particularly to metal diaphragms, the diaphragm may
be permanently damaged and cause improper operation.
P1 > P2 > P
Load
Pressure reversal is normally caused by the inlet pressure
to a regulator being interrupted (automatically or manually).
1. On initial start-up with your system op er at ing at
nor mal conditions, check the differential gauge to
ensure the desired differential pressure is being
maintained. If not, go to step 2 and make one fi nal
ad just ment. (This should only be nec es sary on
fi rst start-up.) NOTE: It is crucial that the ad just ing
screw (6) threads not be dam aged. Do not use
any type of pliers on the adjusting screw (6).
2. To adjust differential setting, use one of the two
following methods: (NOTE: Both methods re quire a fl owing condition.)
a. Loosen the closing cap (28) by turning CCW
(as viewed from above) 3 to 4 complete rev o lu tions. Loos en lock nut (7) by turning CCW
until it is tight (dou ble-nutted) against closing
cap (28). Now the dif fer en tial set ting may be
ad just ed by turn ing the closing cap (28) CW
to increase dif fer en tial or CCW to de crease.
After desired setting is reached, loos en lock
nut (7) from clos ing cap (28) and tighten each
se cure ly to spring cham ber (2).
b. Remove closing cap (28) from ad just ing screw
(6) by turning CCW. Loosen lock nut (7) by
turning CCW. Adjust the differential setting by
turning the ad just ing screw (6) CW to in crease
dif fer en tial pres sure or CCW to de crease.
Tight en lock nut (7) se cure ly to spring chamber
(2). Re place closing cap (28) and tighten.
SECTION V
V. SHUTDOWN
REFER TO THE COM PRES SOR / EXPANDER MAN U FAC TUR ER'S MANUAL FOR DETAILED SHUTDOWN
OF THIS UNIT.
2
IOM-HP-S-DIFF
VI. MAINTENANCE
SECTION VI
WARNING 1
SYSTEM UN DER PRES SURE. Prior to per form ing 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 unit
from the pipeline where in stalled.
2. Owner should refer to owner's procedures for
removal, handling, cleaning and dis pos al of
nonreusable parts, i.e. gaskets, etc.
3. Refer to Figure 3 for view of regulator.
WARNING 2
SPRING UNDER COMPRESSION. Relieve spring compression prior to re mov ing diaphragm fl ange bolts .
Fail ure to so may result in fl ying parts that could cause
per son al injury.
CAUTION D
When body fl ange hardware (9,23,34,35) is re moved from
this unit it should al ways be replaced with new. The new
hardware (9,23,34,35) must have the prop er grade spec i fi ca tion iden ti fi ca tion markings and meet the following
standards:
1. All cap screws (23) and fl ange stud nuts (9) must have
"heavy hex heads".
2. All studs (34,35) and cap screws (23) must comply with
or exceed the requirements of ASTM A-193, Grade B7.
3. All fl ange stud nuts (9) must comply with or exceed
the requirements of ASTM A-194, Grade 2H.
New body fl ange hardware (9,23,34,35) may be pur chased
from Cashco, Inc. or through the OEM.
CAUTION C
DO NOT AT TEMPT TO REMOVE ADJUSTING SCREW (6)
FROM TOP OF SPRING CHAM BER (2). The ad just ing
screw (6) is threaded upward from inside the spring chamber (2). The CCW ro ta tion used to relieve range spring (14)
tension will come to a stop. At the stop ping point, do not
apply any torque to ad just ing screw (6) or dam age may
occur and ren der the unit in op er a ble. See Figure 1.
B. Diaphragm Replacement:
1. Securely install the body (1) in a vise with the
spring chamber (2) directed upwards.
2. To relieve range spring (14) compression,
re move clos ing cap (28) by turning CCW.
Re move lock nut (7) by turning CCW. Turn
ad just ing screw (6) CCW until range spring
(14) compression is relieved. NOTE: See CAUTION C).
3. Draw or embed a match mark between body
(1) casting, body spacer (24), and spring
cham ber (2) casting along fl anged area.
4. Remove all body flange hardware
(9,23,34,35).
5. Remove spring chamber (2), range spring
(14), spring button (4), pressure plate (3), body
spacer (24), diaphragm (12), and o-rings (30).
IOM-HP-S-DIFF
Figure 1: Adjusting screw (6) o-ring inspection.
6. Adjusting screw (6) o-ring inspection:
a. With locknut (7) and closing cap (28)
re moved, turn adjusting screw (6) CW as
far as possible by turning fl ats on top end.
Care ful ly reach inside spring cham ber (2)
and grasp ad just ing screw (6) by hand.
NOTE: For 1/2" (DN15) and 3/4" (DN20)
size reg u la tors a small piece of plastic
tubing with a 3/4" (19 mm) inside di am e ter may be used to grasp the ad just ing
screw (6). Complete ad just ing screw (6)
removal by ro tat ing CCW. See Figure 1.
b. Inspect the backup ring (32) and quad
ring (31) for wear. If nicked or torn - replace. NOTE: Make certain the tefl on
backup ring (32) will insert into spring
cham ber (2) before the quad ring (31).
(See Fig ure 3 blow-up illustration). Make
sure the quad ring (31) is on straight with
no twist. Use a good grade light weight
grease on both ring seals (31,32).
3
c. Lubricate adjusting screw (6) threads.
Carefully re in stall the adjusting screw (6)
up into the spring cham ber (2) by ro tat ing
the ad just ing screw (6) CW until top of
adjusting screw (6) protrudes from top of
spring chamber (2). NOTE: Care should
be taken when hold ing and ro tat ing the
ad just ing screw (6) so the quad ring (31)
and back up ring (32) are not in ad vert ent ly
nicked or torn. Grasp top of ad just ing
screw (6) and turn CCW until ro ta tion
stops (see CAUTION C). See Fig ure 1.
d. Loosely install lock nut (7) and closing cap
(28).
7. In spect pressure plate (3) for defects due to
over-pres sur iza tion. Replace if de fec tive.
8. Clean all parts to be re-used according to
owner's procedures.
9. Place fi rst o-ring (30) on body (1) and lu bri-
cate with a lightweight multi-purpose grease.
Po si tion body spacer (24) on body with match
marks aligned. Place pusher plate (11) on
body spac er (24) and check for ver ti cal move ment. NOTE: The vertical move ment should
be free and unobstructed as the push er plate
(11) is pushed down and the lower piston
spring (17) contracts and ex pands. If move ment is not free, go to Sub sec tion C following
to inspect the inner trim parts.
spacer (24). Thread on lower nuts (9) and
tighten by hand. Adjust length of studs (34,35)
by using the top nut (9) so that there are at least
3 to 4 threads protruding from the lower nut.
Torque body fl ange hardware (9,23,34,35)
using small increments in a 180° al ter nat ing
pattern until fl ange mating sur fac es of body (1),
body spacer (24) and spring chamber (2) are
metal to metal. This creates a "fi xed compres-
sion" on the di a phragm (12) and o-ring (30)
seals. Rec om mend ed torque val ues are listed
in Table 1.
TABLE 1
Body Size
in. (DN)
1/2"-1" (15-25)
1-1/2" (40)
Item
No.
9,23,343/8"-2435-40(47-54)
9,23,34,357/16"-2055-60(75-81)
Thread
Size
Torque Values
Ft-lbs (N-m)
14. With locknut (7) tight against closing cap (28),
turn closing cap (28) CW until tension is ap plied to range spring (14).
15. Proceed to Section D. for bench test.
C. Trim Replacement:
NOTE: Do not release tension on range
spring (14). (Only necessary when removing
spring cham ber). The range spring (14) ten sion keeps pusher plate (11) in alignment and
as sures proper fi t upon replacement of trim.
10. Place second o-ring (30) on body spacer (24)
and lubricate with lightweight multi-purpose
grease. Po si tion diaphragm (12) on body
spac er (24) in side of o-ring (30).
11. Visually center the pressure plate (3) on
di a phragm (12). Place range spring (14) onto
re tain er hub of pressure plate (3).
12. Place multi-purpose, high temperature grease
into depression of spring button (4) where adjusting screw (6) bears. Set spring but ton (4)
onto range spring (14); ensure spring button
(4) is laying fl at.
13. Using "NEW" studs (34,35) and nuts (9) (see CAUTION D), thread a nut onto each stud
approximately 1.25" (32 mm). Drop the studs
(34,35) with nuts (9) through the holes in
spring chamber (2). (This will assist in keep ing the spring chamber (2) centered on body
(1) and prevent parts from moving dur ing reassembly).
Using the "match marks" made in Step 3 as a
guide, replace spring chamber (2) onto body
1. Install body (1) in a vise with the body cap (5)
on top and spring chamber (2) downwards.
2. Loosen and remove body cap (5). NOTE:
Pis ton spring (17) may stick in body cap (5)
when removing.
3. Remove piston spring (17), piston (15) and
cylinder (16). Inspect parts for ex ces sive wear,
espe cially at piston (15) seat surface. En sure
there are no nicks or foreign particles em bed ded in the piston (15) TFE seat. Re place
piston w/ TFE seat (15) if necessary. In spect
the back up ring (27) and quad ring (26) on
piston (15). Re place rings if worn, nicked, or
de pressed.
4. Remove body cap O-ring (25). Clean con tact ing surfaces of body (1) and body cap (5). Be
care ful not to scratch either surface. In spect
inside sur face of the body cap for scratch es or
nicks. These could result in leak age past the
quad ring (26) and backup ring (27). If worn or
scratched replace body cap (5).
4
IOM-HP-S-DIFF
5. Clean debris from within the regulator body
(1) cav i ty. Make certain the old cylinder gas ket
(18) is cleaned out of the body (1) recess.
Clean all parts to be reused according to
owner's procedures.
6. Reinstall a new cylinder gasket (18). Press
fi rmly and evenly into place using the cyl in der
(16). Do not use a “homemade” cylinder gas ket. Pipe seal ant may be lightly coated to
the gasket (18) surfaces prior to installation.
In spect to see that cylinder gasket (18) is
com plete ly pressed into place and cylinder
(16) is cen tered with body cap (5) opening.
7. Install a new back up ring (27) and quad ring
(26) on piston (15). Make certain the tefl on
back up ring (27) will insert the body cap (5)
fi rst, before the quad ring (26) (See Figure 3).
Make sure the quad ring (26) is on straight with
no twist. Use a good grade lightweight grease
on both ring seals (26,27). Slide piston (15)
into cyl in der (16).
8. Place piston spring (17) into the cavity of the
piston (15).
9. Insert new body cap o-ring (25) into groove of
body cap (5). Use a good grade lightweight
grease on body cap o-ring (25). Use pipe
thread seal ant ap plied to the body cap (5)
threads. Screw body cap (5) into body (1).
Impact until body cap (5) is metal to metal
against body (1) at the body cap (5) shoulder.
D. Bench test for suitable operation (Test Fluid:
Air or compressed gas).
NOTE: Reg u la tors are not tight shutoff devices.
Even if pres sure builds up beyond setpoint, a
reg u la tor may or may not develop tight shutoff.
1. Check for internal trim leakage: With No. 1
shut-off valve closed and No. 2 shut-off valve
cracked open, turn on inlet op er at ing pres sure. Fol low in struc tions from SEC TION IV-2.
and set a differential pres sure of 20 psig (1.4
Barg) in the down stream line (No. 2 Gauge).
Close No. 2 shut-off valve and check for tight
shutoff. NOTE: Seat leakage not to exceed 15
bub bles per minute. Do not allow ex ces sive
build up if seat leak age ex ists (crack open
No. 2 shut-off valve to pre vent build up). If
seat leak age is ex ces sive, pro ceed with the
fol low ing steps to de ter mine location of leak:
a. Close No. 1 shut-off Valve.
b. Turn off inlet operating pressure (P1).
c. Re move entire topworks per SEC TION
VI-B., steps 1-5.
Figure 2: Recommended Bench Test
Piping Schematic for HP-1+6+S
d. Turn inlet operating pressure (P1) on.
e. Spray liquid leak detector in the space be-
tween cylinder (16) and body (1) to check
for cylinder gasket (18) leakage.
f. Pour a few drops into recess along pis ton
post (15) to check for seat leakage.
g. Fill the recess to check for quad ring (26)
leakage.
Once location of leak is detected, proceed to
SECTION VII-6 for Cause/Remedy and SECTION VI-C. for internal trim replacement. After
leak is remedied, proceed to SEC TION VI-B.,
steps 8-15 to re as sem ble top works.
2. Check regulator performance: With Step No.
1 con di tions met, open and close No. 2 shutoff valve to check reg u la tor's per for mance for
smooth ness and re peat abil i ty.
3. Proof test to check for external leakage:
a. Build inlet pres sure to 1-1/2 times max i-
mum out let pres sure; but not to exceed
1-1/2 times the Max. Out let and Spring
Cham ber Pressure Rat ing (See HP-SDIFF TB, Ta ble 2). Close No. 2 shut-off
valve and crack open No. 1 shut-off valve
until full inlet pressure exists in the spring
cham ber (2) and down stream line (No. 2
gauge will reg is ter same pres sure as No.
1 gauge).
b. Spray the entire regulator with a liquid leak
detector and visually inspect for external
leak age. Repair unit if leak is detected.
See SEC TION VI MAINTENANCE.
c. To relieve all pressures simultaneously
(pre vent ing diaphragm (12) damage due
to ex ces sive ∆P across diaphragm (12)),
crack open No. 2 shut-off valve and shut
off inlet pres sure. This will uniformly bleed
off all pres sure con tained within the reg u la tor.
4. Return to Section II for Installation and Sec tion
IV for Startup.
D.Restricted diaphragm movement.D1.Ensure no moisture in spring chamber at temperatures below
In spect the seating. Replace if depressed, nicked or embedded
with debris.
Inspect guides in body cap. If damaged, replace body cap and/or
A2.
piston.
Relocate regulator if necessary.
freeze point.
6
IOM-HP-S-DIFF
5 Sluggish operation.
Possible CauseRemedy
A.Plugged body spacer vent hole.A.Clean vent opening.
B.Plugged piston balance port.B.Re move trim and clean balance port.
C.Fluid too viscous.C.Heat fl uid. Contact factory.
6. Excessive seat leakage.
Possible CauseRemedy
A.Foreign matter on seating surface, erosion of seating surface.A.In spect and replace damaged parts.
B.Quad ring/backup ring damaged, scratched body cap.B.Inspect and replace damaged parts.
C.Cylinder gasket damaged.C.Inspect and replace damaged part.
SECTION VIII
VIII. 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.
–
7
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.
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.
2 Spring Chamber
3 Pressure Plate
4 Spring Button
5 Body Cap
6 Adjusting Screw
7 Lock Nut
9 Flange Stud Nut
11 Pusher Plate
12 Diaphragm
14 Range Spring