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-

2

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.

2

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.

3

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

4

IOM-SAP

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 3" & 4" Sizes:

1. Return to Section VII.B. & C. steps 4 thru 8.

2, Remove seal retainer (37) from plug shoulder.
NOTE: Flat surface of retainer touches guide

bearing.

3. Remove cage (19) and ststic 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.

4. Check the seating surface of the plug for
wear. examine for signs of leakage. If seat
ring or plug shows signs of signifi cant leakage,
determine if op er at ing con di tions - pres sure,
pressure drop, or temperature ex ceed design
lim its. Replace as necessary.

3. Slide seat (21) over the lower end of the cage.
Place cage over plug into the body. Ensure
that the cage/seat are not cocked to one side.

4. Position seat retainer (37) on shoulder of plug.
Install o-ring (39) on inner shoulder of plug.

5. Properly align all three cage (18) bolt holes as
there is only one proper alignment possible.
Use hand to ap ply a down ward force to the
top of the cage (19) until the cage is lowered
suf fi cient ly to engage the cage bolts (18) with
washers (17) into the body (23). Engage all
cage bolts, then tighten the cage bolts in
al ter nat ing one-half rev o lu tion in cre ments
to pull the cage down evenly. Tight en cage
bolts (18) to a torque value of 13-15 Ft-lbs
(17.5-20.5 Nm).

6. Slide dynamic seal (27) over small end of guide
bearing. Ensure u-cup seal (27) is oriented
with the center-open-down wards as shown in
Fig ure 1, as the u-cup seal de pends upon the
P1-Inlet pressure to activate prop er seal ing
ac tion.

7. Reposition the bearing guide (13) over end of
plug and carefully slide it into the cage. Place
a new u-cup seal (35) with the center-open­upwards into the recess at the top of the guide
bearing.

8. Place the seal retainer (36) on top of the guide
bearing and engage cap screws (38) tight into
the guide bearing.

5. Remove spring (22) from within the body (23).

6. Remove seal (28) from body fl ange groove.

7. 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.

E. Main Regulator Reassembly:

For 3/4" - 1" Sizes:

1. Insert the return spring (22) into the body (23).

2. Install non-threaded end of plug (20) into the
bore in the bottom of the body. Fit cage O-ring
seal (15) into the body groove.

IOM-SAP

9. Thread nut (40) on to plug threads and tighten
as follows:

Sizes - 3/4" - 1" Torque 60-70 ft. lbs.

10. 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:

1. Insert the return spring (22) into the body (23).

2. Install non-threaded end of plug (20) into the
bore in the bottom of the body. Fit cage O-ring
seal (15) into the body groove.

5

3. Slide seat (21) over the lower end of the cage.
Place cage over plug into the body. Ensure
that the cage/seat are not cocked to one side.

4. Position seat retainer (37) on shoulder of plug.

NOTE: Flat surface of retainer touches guide
bearing. Install o-ring (39) on inner shoulder

of plug.

5. Align hole in clamp ring (42) with dowel pin
(43) and install clamp ring on cage (19).

6. Slide new dynamic seal (27) over end of guide
bearing. Ensure u-cup seal (27) is oriented
with the center-open-down wards as shown in
Fig ure 1, as the u-cup seal de pends upon the
P1-Inlet pressure to activate prop er seal ing
ac tion.

7. Carefully position guide bearing (13) over
plug and into the cage.

8. Place a new u-cup seal (35) with the center­open-upwards into the recess at the top of the
guide bearing. Place the seal retainer (36) on
top of the guide bearing.

9. Thread nut (40) on to plug threads and tighten.
Torque to 120-130 ft. lbs.

5. Slide new dynamic seal (27) over lower end
of guide bearing. Ensure u-cup seal (27) is
oriented with the center-open-down wards as
shown in Fig ure 1, as the u-cup seal de pends
upon the P1-Inlet pressure to activate prop er
seal ing ac tion.

6. Carefully position guide bearing (13) over plug
and into the cage.

7. Place a new u-cup seal (35) with the center­open-upwards into the recess at the top of the
guide bearing. Place the seal retainer (36) on
top of the guide bearing and engage threads
of cap screw (40) tight into the guide bearing.
Torque to 180 - 200 ft. lbs.

8. Remove this sub-assembly from the vise and
install it inside the body cavity.

9. Place new loading chamber seal (28) in recess
in the body fl ange face. Place new o-ring (41)
on top edge of cage. Set loading chamber on
top of body. Align matchmarks from step B.3.
and insert cap nuts and bolts (11 & 12). Tighten
bolting equally in a star pattern. Torque to
35-40 ft. lbs.

10. 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:

1. Insert the return spring (22) into the body (23).

2. 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.

3. Slide seat (21) over the lower end of the cage.
Lower and position cage over plug. Ensure
that the cage/seat are not cocked to one side.

4. Place seat retainer (37) on shoulder of plug.

NOTE: Flat surface of retainer touches guide
bearing Install o-ring (39) on inside shoulder

of plug.

6

IOM-SAP

SECTION VIII

VIII. TROUBLE SHOOTING GUIDE

When trouble shooting this regulator there are many possibilities as to what may be causing problems. Many
times, the regulator itself is not defective, but one or more of the accessories may be. Sometimes the pro cess
may be causing diffi culties.

The key to effi cient trouble shooting is information and communication. The customer should try to be as precise
as possible in their explanation of the problem, as well as their understanding of the application and operating
con di tions.

It is imperative the following information be provided by the customer:

Fluid (with fl uid properties)
Range of fl ow rate
Range of inlet pressure
Range of outlet pressure
Range of fl uid temperature
Range of ambient temperature

Pressure readings should be taken at every location that pressure plays a role - i.e., regulator inlet (as close as
possible to inlet port), regulator outlet (as close as possible to outlet port), etc.

Below are some of the more common complaints along with possible causes and remedies.

1. Erratic regulation, instability or hunting.

Possible Causes Remedies

A. Sticking of internal parts A. Remove internals, clean, and if necessary, replace.

B. Oversized regulator B. Check actual fl ow conditions; resize regulator for min i mum

and maximum fl ow; if necessary, replace with smaller
regulator.

2. Downstream pressure will not reach desired setting.

Possible Causes Remedies

A. Supply pressure is down (confi irm
on pressure gauge).

B. Undersized regulator. B. Check actual fl ow conditions; resize regulator for minimum

3. Leakage at fl ange.

Possible Causes Remedies

A. Body bolts not torqued properly. A1. Torque to proper value (see Section VII, C. 11.)

B. Pressures may be too
high for regulator design.

A. Increase supply pressure

and maximum fl ow; if necessary, replace with larger regulator.

A2. Failed C-ring seal. Replace seal.

B. Consult factory.

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7

4. Leakage across seat.

Possible Causes Remedies

A. Contamination (debris) in regulator. A1. Remove internals, clean and if necessary, replace sealing

seating elements. *
A2. Install UHP fi lter at inlet.

B. Oversized regulator; plug operates
directly next to seat.

* Excess seat leakage may be diagnosed when a failure of the dynamic side seal has occurred. Inspect both
potential internal leak paths.

C. Failure due to wear. C1. Replace seat.

B. Check actual fl ow conditions; resize regulator for minimum and
maximum fl ow; if necessary, replace with smaller regulator.

C2. Replace all internal trim due wear.

SECTION IX

IX. ORDERING INFORMATION
NEW REPLACEMENT UNIT VS PARTS "KIT" FOR FIELD RE

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.

8

IOM-SAP

NOTES

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-SAP

9

Sizes 3/4" - 1"

Figure 1: Dynamic Side Seals

Item No. Description

4 Loading Chamber
11 Flange Nuts
12
13 Guide Bearing
15
17 Cage Washer
18 Cage Cap Screw
19 Cage
20 Plug
21 * Seat
22 Return Spring
23 Body
24 Bushing (3" & 4" sizes)

10

*

Flange Bolts

Cage Seal

Item No. Description
27
28 * Flange Seal
35 * Seal (u-cup)
36 Seal Retainer
37 Seal Retainer
38 Cap Screw
39 * O-ring
40 Nut (Cap Screw 3" & 4" sizes)
41 * O-ring (3" & 4" sizes)
42 Clamp Ring (2" size)
43 Dowel Pin (2" size)

Recommended Repair Parts

*

Dynamic Side Seal (u-cup)

*

IOM-SAP

Sizes 2"

Sizes 3" & 4"

IOM-SAP

11

Cashco, Inc.
P.O. Box 6
Ellsworth, KS 67439-0006
PH [phone]
Fax. # [phone]
www.cashco.com
email: [e-mail]

Printed in U.S.A. SAP-IOM

Cashco GmbH
Handwerkerstrasse 15
15366 Hoppegarten, Germany
PH [phone]
Fax. No. [phone]
www.cashco.com
Email: [e-mail]

Cashco do Brasil, Ltda.
Al.Venus, 340
Indaiatuba - Sao Paulo, Brazil
PH [phone]
Fax. No.
www.cashco.com
Email: [e-mail]