Cashco HP-1-6-S User Manual

INSTALLATION, OPERATION & MAINTENANCE MANUAL (IOM)
MODEL HP-1+6+S
HIGH PRESSURE DIFFERENTIAL
REDUCING REG U LA TOR
SECTION I
IOM-HP-S-
DIFF
12-13
I. DESCRIPTION AND SCOPE
) 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 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
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 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 te 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.
9,23,34 3/8"-24 35-40 (47-54)
9,23,34,35 7/16"-20 55-60 (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 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) 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.
IOM-HP-S-DIFF
5
SECTION VII
VII. TROUBLE SHOOTING GUIDE
1. Erratic operation; chattering.
Possible Cause Remedy
A. Oversized regulator; inadequate rangeability. A1.
B. Worn piston; inadequate guiding. B. Replace trim.
C. Weakened/broken piston spring. C. Replace piston spring. De ter mine if corrosion is causing the failure.
D. Unstable loading pressure. D. Stabilize loading pressure; i.e. pump, control valve, etc.
2. Downstream pressure will not reach desired setting.
Possible Cause Remedy
A. Regulator undersized; A1.
B. Plugged trim. B. Re move trim and check for plugged holes in cylinder.
C. Incorrect range spring (screwing in adjusting screw CW does not
bring pressure up to proper level).
D.
Too much proportional band (droop); outlet (P2) pressure droops
below load pressure (P
E. Restricted diaphragm movement. E. En sure no moisture in spring chamber at temperatures below freeze
LOAD
).
Check actual fl ow conditions, resize regulator for minimum and maximum fl ow.
A2.
Increase fl ow rate.
A3.
Decrease regulator pressure drop; decrease inlet pressure by placing a throttling orifi ce in inlet piping union.
A4.
Install next step higher range spring. Contact factory.
A5.
Before replacing regulator, contact factory.
If so, consider NACE acceptable trims.
Con fi rm by opening bypass valve together with regulator.
A2.
Check actual fl ow conditions, resize regulator; if regulator has inad- equate ca pac i ty, replace with larger unit.
Re place range spring with proper higher range.Contact factory.
C.
D1.
Re view Proportional Band (droop) expected.
D2.
Con tact factory.
point.
3. Leakage through body spacer vent hole, or mixing of fl uids.
Possible Cause Remedy
A. Normal-life diaphragm failure. A1.
B. Abnormal short-life diaphragm failure. B1.
Re place diaphragm. Check actual fl ow conditions, resize regulator; if regulator has inad-
A2.
equate ca pac i ty, replace with larger unit.
Can be caused by excessive chattering. See VII - 1. to remedy chatter.
B2.
Can be caused by corrosive action. Consider NACE acceptable trims. En sure not subjecting to over-temperature conditions.
B3.
Down stream outlet (P2) pressure buildup occurring that overstresses
B4.
di a phragms. Protect with safety relief valve.
Inlet (P1) pressure valve is shutoff while loading (P
B5.
is still on.
LOAD
) pressure
4. Excessive pressure downstream.
Possible Cause Remedy
A. Regulator not closing tightly. A1.
B. Downstream block. B. Check system; isolate (block) fl ow at regulator inlet - not outlet.
C. No pressure relief protection. C. In stall safety relief valve, or rupture disc.
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 Cause Remedy
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 Cause Remedy
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.
IOM-HP-S-DIFF
7
28
7
6
32
31
*
*
Seal Welded per ASME BPVC Code Section IX
2
*
*
34 35
9
*
3
24
11
1
18
*
*
32
*
31
4
14
1/2" (DN15) female NPT Loading Connection.
23
*
12
*
30
*
16
*
6
16
*
18
*
TFE SEAT
15
*
26
*
15
*
17
*
Cashco, Inc. P.O. Box 6 Ellsworth, KS 67439-0006 PH (785) 472-4461 Fax. # (785) 472-3539 www.cashco.com email: sales@cashco.com
Printed in U.S.A. IOM-HP-S-Diff
FIGURE 3
Model HP-1+6+S
Repair Item No. Description Parts
1 Body
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
Cashco GmbH Handwerkerstrasse 15 15366 Hoppegarten, Germany PH +49 3342 4243135 Fax. No. +49 3342 4243136 www.cashco.com Email: germany@cashco.com
Cashco do Brasil, Ltda. Al.Venus, 340 Indaiatuba - Sao Paulo, Brazil PH +55 11 99677 7177 Fax. No. www.cashco.com Email: brazil@cashco.com
*
26 27
25
*
*
27
*
5
Repair Item No. Description Parts
15 Piston w/ TFE Seat 16 Cylinder 17 Piston Spring 18 Cylinder Gasket 23 Cap Screw 24 Body Spacer 25 Body Cap O-Ring
*
*
26 Quad Ring 27 Backup Ring 28 Closing Cap 30 O-ring (2 req'd) 31 Quad Ring 32 Backup Ring 34 Stud 35 Stud
* * * * *
* *
*
* * * * *
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