INSTALLATION, OPERATION & MAINTENANCE MANUAL (IOM)
MODEL SAP
ULTRA HIGH PURITY, PRESSURE LOADED
PRESSURE REDUCING REGULATOR
SECTION I
I. DESCRIPTION AND SCOPE
Model SAP is a piston operated, pressure reducing regulator used to control downstream (outlet or P2) pressure. Sizes are
3/4" (DN20), 1" (DN25), 2" (DN50), 3" (DN80) and 4" (DN100).
II. REFERENCES
SECTION II
IOM-SAP
11-13
Refer to Technical Bulletin SAP-TB for tech ni cal
specifi cations.
CAUTION
Installation of adequate overpressure pro tec tion
is recommended to pro tect the reg u la tor and all
downstream equip ment from dam age in the event
of reg u la tor failure.
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 loading chamber
(4) upwards.
ABBREVIATIONS
CCW – Counter Clockwise
CW – Clockwise
ITA – Inner Trim Assembly
SECTION III
CAUTION
DO NOT HYDROSTATIC TEST THROUGH AN
IN STALLED UNIT; ISOLATE REGULATOR FROM
TEST. The "Outlet" rating as printed on the nameplate is the rec om mend ed “upper op er at ing limit”.
Higher pres sures could cause internal dam age.
In ad di tion, note on the nameplate that the Inlet
and Outlet pres sure and temperature ratings are
at different levels.
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.
Recommended Piping Schematic
for Pressure Reducing Station
SECTION IV
IV. PRINCIPLE OF OPERATION
1. When a loading pressure – P
top side of a guide bearing, the outlet controlled
pressure – P2 – will balance at approximately
.90 – .98 of the loading pressure - PL. (NOTE:
Fluc tu a tions in P1 – Inlet Pressure will cause a
deviation in P2 – Outlet Pressure due to inverse
sym pa thet ic ratio effect.)
– is applied to the
Load
V. STARTUP
1 Start with the block valves closed.
2. Adjust the loading system pressure control de vice
so that main regulator is trying to be con trolled at
0 psig pressure.
3. 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. Closely monitor outlet
(down 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.
SECTION V
2. Movement occurs as pressure variations register
on the guide bearing. The registering pressure is
the outlet, P
ing pressure fl uid op pos es upward move ment.
As outlet pres sure drops, the loading pressure
push es the guide bearing down, opening the port;
as outlet pres sure increases, the guide bearing
pushes up and the port opening closes.
3. A loss of loading pres sure while inlet pressure is
imposed will cause the regulator to fail close.
tor is fl owing. If not, slowly increase the loading
pressure into the cover dome until fl ow be gins.
6. Continue to slowly open the inlet (upstream) block
valve until fully open.
7. Continue to slowly open the outlet (downstream)
block valve, especially when the downstream
piping system isn’t pressurized. If the outlet pressure exceeds the desired pres sure, close the inlet
block valve and go to Step 2. Close bypass valve
approximately 25%, and re peat pro ce dure.
8. When fl ow is established steady enough that the
outlet (downstream) block valve is fully open, begin
to slowly close the bypass valve if installed.
, or downstream pressure. The load-
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CAUTION
Do not walk away and leave a bypassed reg u la tor unattended!
4. Crack open the outlet (downstream) block valve
to approximately 10% full open.
5. Slowly open the inlet (upstream) block valve to
about 25% open, observing the outlet (down stream) pres sure gauge. Determine if the reg u la-
VI. SHUTDOWN
1. Shutoff auxiliary loading pressure source. Close
inlet block valve.
2. Allow suffi cient time for the line pressure down-
stream of the inlet block valve to bleed down.
3. Close the outlet block valve.
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9. Develop system fl ow to a level near its expected
normal rate, and reset the regulator set point by
increasing the loading pressure to increase outlet
pressure, or decreasing the loading pressure to
reduce outlet pres sure.
10. Reduce system fl ow to a minimum level and ob-
serve pressure set point. Outlet pressure will rise
from the set point of Step 9. The maximum rise
in outlet pressure on decreasing fl ow should not
exceed the stated upper limit of the range spring
by greater than 10%. If it does, consult factory.
SECTION VI
4. Relieve the trapped upstream and down stream
pres sure and any loading pres sure.
5. The regulator may now be disassembled for
inspection and pre ven ta tive main te nance while
in-line.
IOM-SAP
SECTION VII
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.
B. Main Regulator Disassembly:
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.
1. Shut down system in accordance Section VI.
2. Disconnect loading pressure supply line from
loading chamber. Loosen cover bolts (12) and
nuts (11) uniformly and remove from regulator.
3. Place matchmarks on body (23) and loading
chamber (4) fl anges. Remove the loading
cham ber by lifting vertically. NOTE: Seal (28)
may fall out of loading chamber recess.
C. To replace the guide bearing and dynamic seals
and plug o-ring:
For 3/4" - 1" Sizes:
4. Rotate cap screws (38) CCW and remove.
Lift seal retainer (36) up to remove seal (35).
5. Grasp the upper part of the plug (20) with a
wrench and with a second wrench rotate nut
(40) CCW to remove nut.
off end of guide bearing and replace with new
seal. Ensure seal's u-cup is oriented with the
center-open-downwards as shown in Fig ure
1, as the u-cup seal de pends upon the inlet
pressure to activate prop er seal ing ac tion.
7. Carefully remove o-ring (39) from shoulder of
plug and replace with new o-ring.
8. Reposition the bearing guide (13) over end of
plug and carefully slide it down into the cage.
Place a new u-cup seal (35) with the centeropen-upwards into the recess at the top of the
guide bearing.
9. Place the seal retainer (36) on top of the guide
bearing and engage cap screws (38) tight into
the guide bearing.
10. Thread nut (40) on to plug threads and tighten:
Sizes - 3/4" - 1" Torque 60-70 ft. lbs.
11. Place new loading chamber seal (28) in recess
in the body fl ange face. Set loading chamber on
top of body. Align matchmarks from step B.3.
and insert nuts and bolts (11 & 12). Tighten
bolting equally in a star pattern - torque to
35-40 ft. lbs.
For 2" Size:
4. Grasp the upper part of the plug (20) with a
wrench and with a second wrench rotate nut
(40) CCW to remove nut.
5. Lift seal retainer (36) up and over threaded
end of plug (20) to remove piston seal (35).
6. Using hands, grasp guide bearing (13) and lift
upwards to remove. Slide dynamic seal (27)
off end of guide bearing and replace with new
seal. Ensure seal's u-cup is oriented with the
center-open-down wards as shown in Fig ure
1, as the u-cup seal de pends upon the inlet
pressure to activate prop er seal ing ac tion.
7. Carefully remove o-ring (39) from shoulder of
plug and replace with new o-ring.
8. Reposition the bearing guide (13) over end of
plug and carefully slide it down into the cage.
Place a new u-cup seal (35) with the centeropen-upwards into the recess at the top of the
guide bearing.
IOM-SAP
6. Using hands, grasp guide bearing (13) and lift
upwards to remove. Slide dynamic seal (27)
9. Place the seal retainer (36) on top of the guide
bearing.
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10. Thread nut (40) on to plug threads and tighten:
Torque 120-130 ft. lbs.
11. Place new loading chamber seal (28) in recess
in the body fl ange face. Set loading chamber on
top of body. Align matchmarks from step B.3.
and insert nuts and bolts (11 & 12). Tighten
bolting equally in a star pattern - Torque to
35-40 ft. lbs.
For 3" & 4" Sizes:
4. Place hands around O.D. of the cage (19) and
lift the complete guide bearing and plug subassembly out of the body. Secure the lower
part of the valve plug (20) in a bench vise;
grasp in "smooth jaws" directly under plug's
seating disc portion on hub "fl ats" provided.
Do not hold on the ma chined sur face in the
plug's spin dle area.
5. Use a wrench to rotate cap screw (40) CCW
and remove.
6. Lift retainer (36) up and over threaded end of
plug (20). Remove seal (35) and o-ring (41).
7. Using hands grasp the guide bearing (13) and
lift upwards to remove. Slide dynamic seal (27)
off end of guide bearing and replace with new
seal. Ensure seal's u-cup is oriented with the
center-open-down wards as shown in Fig ure
1, as the u-cup seal de pends upon inlet pressure to activate prop er seal ing ac tion.
8. Carefully remove o-ring (39) from shoulder of
plug and replace with new o-ring.
9. Place a new u-cup seal (35) with the centeropen-upwards into the recess at the top of the
guide bearing. Reposition the bearing guide
(13) over end of plug and carefully slide it
down into the cage.
10. Place the seal retainer (36) on top of the guide
bearing. Engage cap screw (40) tight onto
the guide bearing. Torque to 180 - 200 ft. lbs.
11. Place new loading chamber seal (28) in recess
in the body fl ange face. Place new o-ring (41)
in groove in top of guide bearing. Set loading
chamber on top of body. Align matchmarks
from step B.3. and insert nuts and bolts (11 &
12). Tighten bolting equally in a star pattern.
Torque to 35 - 40 ft. lbs.
D. To replace the seat:
For 3/4" - 1" Sizes:
1. Return to Section VII.B. & C. steps 4 thru 7.
2. Remove seal retainer (37) from plug shoulder.
3. Evenly loosen the cage cap screws (18) CCW
in single revolution increments. The reg u la tor
con tains a return spring (22); the cage should
rise as the cage cap screws are backed out
evenly. Using hand pressure apply downward
force to the top of the cage to pre vent the cage
from pop ping up as the last threads of the
cage cap screws are disengaged. Remove
washers (17).
4. Remove the cage and static seal (15) from
the body. NOTE: Seat (21) maybe stuck to
the bottom of the cage as cage is removed.
If not, remove seat from body cavity.
5. Check the seating surface of the plug for
wear. Examine for signs of leakage. If seat
ring or plug show signs of signifi cant leakage,
determine if op er at ing con di tions - pres sure,
pressure drop, or temperature ex ceed ddesign
lim its. Replace as necessary.
6. Remove spring (22) from within the body (23).
7. Remove seal (28) from body fl ange groove.
8. 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. Go to Step E.
For 2" Size:
1. Return to Section VII.B. & C. steps 4 thru 7.
2. Lift clamp ring (42) up to remove. Not necessary to remove dowell pin (43).
3. Remove seal retainer (37) from plug shoulder.
NOTE: Flat surface of retainer touches guide
bearing.
4. Remove cage (19) and static seal (15) from
the body. NOTE: Seat (21) maybe stuck to
the bottom of the cage as cage is removed.
If not, remove seat from body cavity.
5. Check the seating surface of the plug for
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IOM-SAP