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
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
Loading...