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INSTALLATION, OPERATION & MAINTENANCE MANUAL (IOM)

IOM-DA0

11-13

I. DESCRIPTION AND SCOPE

Model DA0 is a pressure reducing regulator used to control downstream (outlet or P2) pressure. Sizes are

1/2" (DN15), 3/4" (DN20), 1" (DN25), 1-1/4" (DN32), 1-1/2" (DN40), 2" (DN50), 3" (DN80) and 4" (DN100). Refer

to Technical Bulletin DA0-TB for design conditions and selection recommendations. (NOTE: This product was

formerly identiﬁ ed as a Model D0; a Model DA0 and D0 are one and the same product.)

This manual does not include instructions related to the various methods of pressure loading a Model DA0

main valve.

MODEL DA0

DIRECT-ACTING, PRESSURE LOADED

PRESSURE REDUCING REGULATOR

for STEAM APPLICATIONS

II. REFERENCES

Refer to Technical Bulletin DA0-TB and DAG-TB

for tech ni cal speciﬁ cations for this reg u la tor.

ABBREVIATIONS

CW – Clockwise

CCW – Counter Clockwise

ITA – Inner Trim Assembly

III. INSTALLATION

SECTION III

SECTION II

SECTION I

1. Regulator may be rotated around pipe axis 360

degrees. For ease of maintenance, the rec om-

mend ed position is with the cover dome (25)

up wards.

2. Provide space below, above, and around reg u la-

tor for removal of parts during maintenance.

3. Install block valves and pressure gauges to pro-

vide means for adjustment, operation, bypass,

or removal of the regulator. A pipeline strainer

is recommended before inlet to remove typical

pipe line debris from entering valve and damaging

internal “soft goods”, primarily the dynamic seal.

4. Steam traps should be installed before and after

the regulator to provide proper drainage.

5. Install the regulator with the ﬂ ow in the direction

of the arrow cast or stamped into the body.

6. For best performance, recommend that the pip-

ing upstream and downstream of the regulator

be straignt and free from any restrictions, bend,

etd. which can cause turbulence, for a minimun

length of approximately ﬁ fteen to twenty pipe

diameters.

7. Pipe size should be given special consideration,

particularly downstream of the regulator, to

ensure that the steam velocity does not exceed

industry or customer guidelines. Reference

DAG-TB, Table DAG-11 for rec om men da tions

for applying external pressure sensing.

8. External sensing, uses an external control line.

This line is connected from the 1/4" (DN8) NPT

tap on the side of the pilot body to a pressure

tap down stream of the regulator. Use 1/4" or

3/8" (DN8 or 10) outer di am e ter tubing or 3/8"

(DN10) pipe having an inner di am e ter equiv a lent

to Schedule 40 pipe. For condensable vapors (i.e.

steam) slope the external sensing line downward

2 to 5 de grees to outlet piping to prevent water

pock ets, which allows the diaphragm chamber

to always be self draining.

CAUTION

Installation of adequate overpressure pro tec tion is recom-

mended to pro tect the reg u la tor from overpressure and

all down stream equip ment from damage in the event of

regulator failure.

Summary of content (12 pages)

PAGE 1
INSTALLATION, OPERATION & MAINTENANCE MANUAL (IOM) IOM-DA0 11-13 MODEL DA0 DIRECT-ACTING, PRESSURE LOADED PRESSURE REDUCING REGULATOR for STEAM APPLICATIONS SECTION I I. DESCRIPTION AND SCOPE Model DA0 is a pressure reducing regulator used to control downstream (outlet or P2) pressure. Sizes are 1/2" (DN15), 3/4" (DN20), 1" (DN25), 1-1/4" (DN32), 1-1/2" (DN40), 2" (DN50), 3" (DN80) and 4" (DN100). Refer to Technical Bulletin DA0-TB for design conditions and selection recommendations.
PAGE 2
CAUTION DO NOT HYDROSTATIC TEST THROUGH AN INSTALLED UNIT; ISOLATE REGULATOR FROM TEST. The "OUTLET RATING" as printed on the nameplate is the recommended “upper operating limit” for the sensing diaphragm. Higher pressures could cause internal damage. In addition, note on the nameplate that the Inlet and Outlet pressure and temperature ratings are at different levels.
PAGE 3
9. Develop system flow to a level near its expected normal rate, and reset the regulator set point by adjusting the loading system pressure control setpoint to the desired outlet pressure level. 10. Reduce system flow to a minimum level and observe pressure set point. Outlet pressure will rise from the set point of Step 9 for a Model DA0. The maximum rise in outlet pressure on decreasing flow should not exceed the 10%. If it does, consult factory. SECTION VI VI. SHUTDOWN 1. Shutoff inlet block valve. 4.
PAGE 4
WARNING the "pressed-in-place" lower guide bushing (24) and the surface can not be marred. 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. B. Main Valve Disassembly: 1. Shut down system in accordance Section VI. 2. Disconnect the external piping line(s) connecting pilot to main regulator. 3.
PAGE 5
11. Clean all reusable metal parts according to owner's procedures. D. Inspection of Parts: 1. After inspection remove from the work area and discard the old “soft goods” parts (i.e. o-rings, seals, gaskets, etc.) after inspection. These parts MUST be replaced with factory supplied new parts. 2. Inspect the metal parts that will be reused. The parts should be free of surface contaminants, burrs, oxides, and scale. Rework and clean parts as necessary.
PAGE 6
piston ring seal “slips inside” the cage (19). Repeat process for second piston ring seal . 7. Place properly oriented seat ring (21) onto its shoulder at the lower end of cage (19). 8. Install new lower stem o-ring seal (14) into groove of plug (20). 9. Insert plug (20) upwards through lower end of cage (19) and through the center hole in piston-guide bearing (13), wiper washer (17) and wiper seal (16). Hold plug (20) and cage (19) assembly together. 10.
PAGE 7
2. Inboard Leakage Test. a. Release all loading pressure in cover dome. b. Pressurize inlet to 30 psig (2.1 Barg) with air, GN2. c. Tube outlet to a beaker of water to observe number of escaping gas bubbles. Inboard leakage path may be via plug/seat or dynamic side seal. 3. Pressure Containment Test. a. Pressurize inlet to 200 psig (13.8 Barg) and outlet and cover dome to 150 psig (10.3 Barg) with air or GN2. b. Spray liquid lead detector and check all external leak points; i.e.
PAGE 8
SECTION VIII VIII. PRESSURE LOADING 1. Loading pressure can be supplied using various schemes. Please reference LOADING SYSTEMS on web-site for the schematics of these various schemes, including: • pressure unloading using BPV • pressure loading using PRV • pressure loading using pilot • pressure loading using I/P transducer 2. The Model DA0 exhibits a deviation in outlet controlled pressure when the inlet pressure varies; this “effect” is identified as ISR – Inverse Sympathetic Ratio.
PAGE 9
SECTION IX IX. 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 process may be causing difficulties. The key to efficient trouble shooting is information and communication.
PAGE 10
SECTION X X. 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 11
Figure 5 Item No. 7 10 11 12 13 14 * 15 * 16 * 17 18 19 IOM-DA0 Description Nut Stop Plate Cap Screws Nuts Guide Bearing Seal Cage Seal Wiper Seal Washer Cage Cap Screws Cage Item No. 20 * 21 * 22 23 24 25 27 * 37 * 90 Description Plug Seat Spring Body Body Bushing Cover Dome Dynamic Seal (see Figure 1) Gasket Washer (on 1/2"- 2" sizes below No.7) * Recommended Repair Parts.
PAGE 12
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. DA0-IOM 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.