Cashco SA5 User Manual
INSTALLATION, OPERATION & MAINTENANCE MANUAL (IOM)
IOM-CA5/SA5
MODEL CA5/SA5
CA5 and SA5 - ULTRA HIGH PURITY, SPRING LOADED
BACK PRESSURE REGULATORS
SECTION I
I. DESCRIPTION AND SCOPE
Models CA5/SA5 are spring operated back pressure regulators used to control upstream (inlet or P1) pressure. Sizes are
3/4" (DN20) and 1" (DN25). With proper trim uti li za tion, the unit is suitable for liquid or gaseous service. (NOTE: This
product was formerly identifi ed as a Model C5 or S5; a Model CA5/SA5 and C5/S5 are one and the same product.)
II. REFERENCES
SECTION II
11-13
Refer to Technical Bulletin CA5/SA5-TB for tech ni-
cal specifi cations of a Model CA5/SA5 reg u la tor.
SECTION III
III. INSTALLATION
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 orientation is with the spring chamber
(4) upwards.
3. Provide space below, above, and around reg u la tor
for removal of parts during maintenance.
4. Install block valves and pressure gauges to pro vide means for adjustment, operation, bypass, or
removal of the regulator. A UHP fi lter is rec om-
mend ed before inlet to remove typical pipe line
debris from entering valve and damaging internal
“soft goods”, primarily the dynamic seal and valve
seat.
ABBREVIATIONS
CCW – Counter Clockwise
CW – Clockwise
ITA – Inner Trim Assembly
CAUTION
DO NOT HYDROSTATIC TEST THROUGH AN
IN STALLED UNIT; ISOLATE REGULATOR FROM
TEST. The upper range spring pres sure level on
the nameplate 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.
Recommended Piping Schematic
For Back Pressure/Relief Station
IV. PRINCIPLE OF OPERATION
SECTION IV
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 pressure
drops, the range spring pushes the di a phragm
V. STARTUP
1 Start with the block valves closed.
2. Relax the range spring by turning the ad just ing
screw (1) 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 to initially pressurize the system while simultaneously controlling
P1 pressure through manual actuation of bypass
valve.
CAUTION
Do not walk away and leave a bypassed reg u la tor unattended!
4. Closely monitor inlet (up stream) pressure via
gauge to ensure not over-pressurizing. NOTE: If
no bypass valve is in stalled, extra caution should
be used in start ing up a cold system; i.e. do everything slowly.
down, closing the port; as inlet pres sure increases,
the diaphragm pushes up and the port opens.
2. A complete diaphragm failure will cause the reg u la tor to fail close and fl uid will discharge from the
spring chamber vent hole.
SECTION V
5. Open the outlet (downstream) block valve.
6. Slowly open the inlet (upstream) block valve to
about 25% open, observing the inlet (up stream)
pres sure gauge. Determine if the reg u la tor is
fl owing. If not, slowly rotate the regulator ad just ing screw (1) CCW (viewed from above) until fl ow
be gins.
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 (1) CW to increase
inlet pressure, or CCW to reduce inlet pres sure.
9. Reduce system fl ow to a minimum level and
observe pressure set point. Inlet pressure will
increase from the set point of Step 7. The maximum 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. 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.)
CAUTION
Do not walk away and leave a bypassed reg u la tor unattended!
2
SECTION VI
2. Remove range spring compression by turning
the adjusting screw (1) CCW to reduce the inlet
pressure.
3. Close the outlet (downstream) block valve.
4. Relieve the trapped upstream and down stream
pres sure.
5. The regulator may now be disassembled for
inspection and pre ven ta tive main te nance while
in-line.
IOM-CA5/SA5
VII. MAINTENANCE
A. General:
1. The regulator may be serviced without re mov ing the regulator from pipeline. The reg u la tor
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, Product Code,
and Serial Number.
3. Refer to Section IX for 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. seals, etc.
5. The Inner Trim is re moved and replaced in the
body ( 23) as an assemblage of parts. The
Inner Trim Assembly, here in af ter called ITA,
consists of the fol low ing parts:
SECTION VII
2. Loosen adjusting screw lock nut (2) and relax
range spring (6) pressure by turning ad just ing screw (1) CCW (viewed from above) until
removed from spring cham ber (4).
3. Loosen the diaphragm fl ange bolts (11) and
nuts (12) uniformly. Remove bolting (11,12).
4. Place matchmarks on body (23) and spring
chamber (4) fl anges. Remove the spring
cham ber (4) by lifting vertically.
5. Remove the ball (14), spring follower (5) and
range spring (6).
6. Remove upper diaphragm pressure plate (8).
7. Remove diaphragm(s) (9) and examine to
de ter mine if failed. If diaphragms (9) failed,
de ter mine if op er at ing con di tions are ex ceed ing
designed pressure or tem per a ture limits.
8. Remove metal C-ring seal (28) from body (23)
di a phragm fl ange groove.
9. Evenly loosen the three cage cap screws (18)
in single revolution increments and remove
screws and washers (17).
Item Dynamic
No. Seal Type Part Description
13 ..................... All ..........................Piston-Guide Bearing
15 .....................All ................................ Cage O-ring Seal
16..................... UC.................................................Shim
19 ..................... All ...................................................Cage
20 ..................... All ...........................................Valve Plug
21 ..................... All ............................................Seat Ring
27 .....................All ............................. Dynamic Side Seal
27.1 .............. CP............................................. Cap Seal
27.2 .............. CP..........................O-ring Energizer/Seal
27.3 .............. UC .......... U-Cup Seal w/Metal Energizer
31 .................... All .............................................Seat Disc
32 .................... All ........................................Disc Washer
34 .................... All ...........................................Cap Screw
6. A detailed view of the dynamic side seal parts
is shown in Figure 1; an assembled ITA in
Figure 2; and a cross-sectional drawing of
the entire regulator is shown in Figure 3.
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.
Type CP - Cap
Dynamic Seal
Type UC - U-Cup
Dynamic Seal
B. Main Regulator Disassembly:
1. Shut down the system in accordance with
Section VI.
IOM-CA5/SA5
Figure 1: Dynamic Side Seals
3
10. Remove the ITA from the cage pull ing up on
the piston-guide bearing (13). Set ITA aside.
11. Remove cage (19), o-ring seals (15) and (21).
e. Remove plug assembly and 3/8" bar stock
pieces from vise and rotate end for end
and secure in vise again.
12. Clean all metal parts to be reused according to
owner's procedures. NOTE: Regulators are
originally supplied with a level of clean li ness
equal to Cashco cleaning standard #S-1662.
Contact factory for details.
C. Disassembly of the ITA:
1. To Disassemble the ITA (See Figure 2):
a. Fit 2 pieces of 3/8" wide x 3" long square
steel bar stock into the fl ats on either
side of the plug and secure snug in the
vise with the lower part (seat end) of the
valve plug (20) down. Do not clamp on
any ma chined, cylindical sur face on the
plug.
f. Using an allen wrench, rotate screw (34)
CCW and remove screw, disc washer (32)
and seat disc (31).
g. Clean all metal parts to be reused ac-
cording to owner's procedures. NOTE:
Regulators are originally supplied with a
level of clean li ness equal to Cashco cleaning standard #S-1662. Contact factory for
details.
D. Inspection of Parts:
1. Remove and dis card the fol low ing parts:
diaphragm(s) (9), o-ring (15), seals (21, 27,
28). 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
below; re place parts that can not be re worked
or cleaned.
Figure 2: Assembled ITA, with
"UC" Dynamic Side Seal
b. Using a special double-posted spanner
wrench fi tting (to order see NOTE in
Section IX, Parts Ordering Information),
turn the pis ton-guide bear ing (13) CCW
to loosen. The piston-guide bear ing (13)
may be re moved by hand after loos en ing.
c. Remove shim (16).
d. Remove and examine the dynamic seal
(27.1, 27.2, 27.3) to de ter mine if sig nifi -
cant leakage was oc cur ring. If the seal
(27) shows signs of leakage, de ter mine
if op er at ing con di tions ex ceed pres sure,
pres sure drop, or tem per a ture lim its.
NOTE:
when using “tools” to remove the plug
and seal to ensure that no scratches
are made to any portion of the plug (20)
groove or plug itself.
Special care should be taken
3. QC Requirements:
a. Valve plug (20);
1. 16 rms fi nish on its seating surface
for tight shutoff.
b. Cage (19);
1. 16 rms fi nish on cage bore. No “ledg-
es” formed due to wear from moving
dynamic side seal (27) or plug (20).
E. Reassembly of the ITA:
1. Secure plug (20) in a vise with seat end up
using the steel bar stock pieces from C. 1.
previous.
2. Place new seat disc (31) and washer (32) over
end of plug (20).
3. Thread screw (34) into plug and torque to
20 - 35 ft-lbs (27 - 47 Nm).
4. Remove plug assembly and 3/8" bar stock
pieces from vise and rotate end for end and
secure in vise, again using the bar stock pieces.
4
IOM-CA5/SA5
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