Cashco SAP User Manual

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-

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.

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.

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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.

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.

10. Thread nut (40) on to plug threads and tighten: Torque 120-130 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

IOM-SAP

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Cashco SAP User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual