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INSTALLATION, OPERATION & MAINTENANCE MANUAL

IOM-1000HP-

Differential

12-13

MODEL 1000HP - DIFFERENTIAL

SECTION I

I. DESCRIPTION AND SCOPE

The Model 1000HP-1+6 and 1000HP-1+8 are dif fer en tial pressure reducing regulators used to control dif fer en tial

pressure between downstream (outlet or P

) pressure and a loading (P

Load

) pressure to the spring chamber. Sizes

are 1/2" , 3/4", 1", 1-1/4", 1-1/2" and 2" (DN15, 20, 25, 32, 40 and 50). With proper trim uti li za tion and jet selection,

this unit is suitable for liquid, gaseous, or steam service. Refer to Technical Bulletin 1000HP-DIFF-TB for sizing,

application and selection rec om men da tions.

SECTION II

II. INSTALLATION

1. An inlet block valve should always be installed.

An outlet block valve is desirable.

2. A manual bypass valve is recommended for “hot

piping” systems to assist in piping warm-up at

startup.

3. An isolation valve on the loading line is not rec om -

mend ed. The annular body ring of the 1000HP-1+8

may be piped to a safe drainage point, but no valve

should be installed in the drain line.

4. Pipe unions must be installed to allow removal

from piping. Trim can only be changed by unit

removal from pipeline. If ﬂ anges are utilized, a

lap joint ﬂ ange is required on the inlet end of the

regulator to help align bolt holes as the cylinder

screws into place. NOTE: Cashco does not rec-

om mend ﬁ eld welding on the cylinder (inlet) end

of the valve due to the possibility of warpage.

CAUTION

Recommended Piping Schematic for

Differential Pressure Reducing Station

DO NOT HYDROSTATIC TEST THROUGH AN IN-

STALLED UNIT; ISOLATE FROM TEST. DO NOT

HY DRO STAT IC TEST THE LOADING PRESSURE

WITH OUT PRESSURE IN THE MAIN REGULATOR.

The name plate indicated outlet pressure rating, if

reached, may cause internal damage. Refer to Tech ni cal

Bulletin Model 1000HP-DIFF-TB, Table 3 for “emer gen cy

overpressure level” that will not do irrepairable internals

damage. In addition, note on the name plate that the

Inlet and Outlet pressure and tem per a ture ratings are

at different levels.

5. An outlet pressure gauge should be located ap-

prox i mate ly ten pipe diameters downstream, and

within sight. A loading pressure (or differential

pressure) gauge is rec om mend ed.

6. All installations should include a downstream re-

lief device if the inlet pressure could exceed the

pressure rating of any downstream equipment or

the maximum outlet pressure rating of the unit.

7. Clean the piping of all foreign material including

chips, welding scale, oil, grease and dirt before

in stall ing the regulator. Strainers are rec om -

mend ed.

8. In placing thread sealant on pipe ends prior to

en gage ment, ensure that excess material is

re moved and not allowed to enter the regulator

upon startup.

9. Flow Direction: Install so the ﬂ ow direction match es

the arrow cast on the body.

SRV

Outlet

@ P

Supply

@ P

(Shaded portion for steam/condensate systems)

Model 1000HP-1+6

Differential

Bypass

Blowdown-Drain Blowdown-Drain

Summary of content (16 pages)

PAGE 1
IOM-1000HPDifferential INSTALLATION, OPERATION & MAINTENANCE MANUAL 12-13 MODEL 1000HP - DIFFERENTIAL SECTION I I. DESCRIPTION AND SCOPE The Model 1000HP-1+6 and 1000HP-1+8 are differential pressure reducing regulators used to control differential pressure between downstream (outlet or P2) pressure and a loading (PLoad) pressure to the spring chamber. Sizes are 1/2" , 3/4", 1", 1-1/4", 1-1/2" and 2" (DN15, 20, 25, 32, 40 and 50).
PAGE 2
10. For best performance, install in well drained horizontal pipe, properly trapped if a steam service application. diaphragm design): Regulator may be rotated around the pipe axis 360° and may be installed in a horizontal or vertical pipeline. 11. Differential Regulator – (Refer to Dwg. Opt-1+6 for single diaphragm or Dwg. Opt-1+8 for double 12. Regulators are not to be direct buried underground. SECTION III III. PRINCIPLE OF OPERATION 1.
PAGE 3
SECTION IV IV. STARTUP rotate the regulator adjusting screw clockwise (CW) until flow begins. 1. Start with the block valves closed. A bypass valve may be used to maintain outlet pressure in the downstream system without changing the following steps. 6. Continue to slowly open the inlet (upstream) block valve until fully open. 2. Remove closing cap and relax the range spring by turning the adjusting screw counterclockwise (CCW) a minimum of three (3) full revolutions.
PAGE 4
SECTION VI (19) is not used with a composition (soft) diaphragm.) VI. MAINTENANCE WARNING SYSTEM UNDER PRESSURE. Prior to performing any maintenance, isolate the regulator from the system and relieve all pressure. Failure to do so could result in personal injury. A. General: 1. Maintenance procedures hereinafter are based upon removal of the unit from the pipeline where installed. 2.
PAGE 5
9. Place the pusher plate stud (13) in a separate vise, gripping the stud (13) on the hexagonal cast-in-place edges located on the underneath side of the pusher plate stud. NOTE: Do not remove the stud nut (10), stud collar (16), and the location locking cotter pin (15). plate (3) over the pusher plate and stud (13). Place nut (11) onto the stud (13) and tighten. Recommended torques are as follows: Body Size 3/8" – 1/2" 3/4" – 1" 1-1/4" – 2" 10. Loosen and remove nut (11).
PAGE 6
25. Check rocker arm shaft (17) for wear and straightness. Replace if damaged. Reinstall in body (1) through rocker arm (14). Apply thread sealant to the rocker arm shaft (17) threads prior to tightening. Make sure that the rocker arm shaft (17) enters the support slot opposite the threaded opening, and does not align crooked and restrained from full thread engagement of the rocker arm shaft (17).
PAGE 7
obtained when the diaphragm is at this value, rather than a lower level. As the measuring of a thousandths of an inch is difficult with such a procedure, it is recommended that the “null” position be found where the diaphragm(s) (20) is flush with the body (1) flange (bar approximately at 0.000"). Remove the pusher plate stud (13), rotate the stud nut (10) one or two slots CCW to bring the setting to 0.010–0.020" (.25–.51 mm) high. 5. Place cotter pin (15) through the slot, bend over ends. 6.
PAGE 8
d. Place thread sealant on threaded portion of seat disc screw (26), and manually rotate piston (24) into seat disc screw (26) (still fixed in vise) to secure seat disc (25). Tighten seat disc screw (26) firmly. Do not over-tighten to the point of embedding the seat disc screw (26) into the seat disc (25); the seat disc (25) should lay flat with no rounded surface. A mechanical aid is normally not required; hand tightening is normally sufficient. 7.
PAGE 9
13. Bench test unit for suitable operation and seat leakage. NOTE: Regulators are not normally tight shutoff devices. Pressure must build above setpoint for best shutoff. 14. Soap solution test around cylinder (21)-tobody (1) connection for leakage. Test pressure should be a minimum of 100 psig at the inlet or actual service conditions if higher. SECTION VII VII. TROUBLE SHOOTING GUIDE 1. Erratic operation; chattering. Possible Causes 9 Remedies A. Oversized regulator; inadequate rangeability. A1.
PAGE 10
2. Regulator differential pressure too low. Possible Causes Remedies A. Setpoint too low. A. Turn adjusting screw down (CW) to increase setpoint. B. Regulator undersized; outlet pressure (P2) droops below loading pressure (PLoad). B1. Confirm by opening bypass valve together with regulator. B2. Check actual flow conditions, resize regulator; if regulator has inadequate capacity, replace with larger unit. C. Plugged inlet strainer. C. Remove strainer screen and clean; consider leaving screen out.
PAGE 11
4. Excessive pressure downstream. Possible Causes Remedies A. Regulator not closing tightly. A1. Overly compressed range spring; i.e. approaching solid height. Use next higher range spring. A2. Inspect the seating. Clean and lap metal seat surfaces; replace if lapping does not remedy. If composition seats are depressed, nicked or embedded with debris, replace seat disk. A3. Diaphragm setting too high; check setting. A4.
PAGE 12
7. Not able to maintain setpoint. Possible Causes A. Diaphragm may be bent due to pressure reversal. Remedies A. Make sure to prevent system reversal. 8. Excess leakage: Possible Causes 12 Remedies A. Faulty seating surfaces. A1. Seat has been nicked by welding splatters. A2. Composition seat is damaged. A3. Composition seat driven into metal seat surface due to overpressure. B. Outlet pressure setting too low for inlet pressure. B. Refer to Technical Bulletin.
PAGE 13
SECTION VIII VIII. ORDERING INFORMATION NEW REPLACEMENT UNIT vs PARTS "KIT" FOR FIELD REPAIR 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).
PAGE 14
MODEL 1000HP-1+6 DIFFERENTIAL PRESSURE REDUCING REGULATOR Item No. 1 2 3 4 6 7 9 10 11 12 13 14 15 16 17 19 20 14 Description Body & Body Assembly Spring Chamber (or Loading Chamber) Pressure Plate Spring Button Adjusting Screw Adjusting Screw Lock Nut Flange Nut Stud Nut Pressure Plate Nut Pusher Plate Gasket Pusher Plate Stud Rocker Arm Cotter Pin Stud Collar Rocker Arm Shaft Diaphragm Gasket Diaphragm Item No. 21 21.1 21.
PAGE 15
MODEL 1000HP-1+8 DIFFERENTIAL PRESSURE REDUCING REGULATOR Item No. 1 2 3 4 6 7 8 9 10 11 12 13 14 15 16 17 15 Description Body & Body Assembly Spring Chamber (or Loading Chamber) Pressure Plate Spring Button Adjusting Screw Adjusting Screw Lock Nut Flange Bolt Flange Nut Stud Nut Pressure Plate Nut Pusher Plate Gasket Pusher Plate Stud Rocker Arm Cotter Pin Stud Collar Rocker Arm Shaft Item No. 19 20 21 21.1 21.
PAGE 16
Cashco, Inc. P.O. Box 6 Ellsworth, KS 67439-0006 PH (785) 472-4461 Fax. # (785) 472-3539 www.cashco.com email: sales@cashco.com Printed in U.S.A. IOM-1000HP-Diff Cashco GmbH Handwerkerstrasse 15 15366 Hoppegarten, Germany PH +49 3342 4243135 Fax. No. +49 3342 4243136 www.cashco.com Email: germany@cashco.com Cashco do Brasil, Ltda. Al.Venus, 340 Indaiatuba - Sao Paulo, Brazil PH +55 11 99677 7177 Fax. No. www.cashco.com Email: brazil@cashco.