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INSTALLATION, OPERATION & MAINTENANCE MANUAL (IOM)

IOM-DA1

11-13

I. DESCRIPTION AND SCOPE

The Model DA1 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).

With proper trim uti li za tion, the unit is suitable for liquid, gaseous, or steam service. Refer to Technical Bulletin

DA1-TB for design conditions and selection recommendations. (NOTE: This product was formerly identiﬁ ed as

a Model D1; a Model DA1 and D1 are one and the same product.)

MODEL DA1

DA1 - DIRECT-ACTING, SPRING LOADED

PRESSURE REDUCING REGULATOR

SECTION I

II. REFERENCES

Refer to Technical Bulletin DA1-TB and DAG-TB for

tech ni cal speciﬁ cations of a Model DA1 regulator.

ABBREVIATIONS

CCW – Counter Clockwise

CW – Clockwise

ITA – Inner Trim Assembly

III. INSTALLATION

pipe line debris from entering valve and damaging

internal “soft goods”, primarily the dynamic seal(27)

and the V-TFE seat (21) when applied.

4. Downstream Sensing Installation Considerations

– Internal or External Sensing:

a. The regulator may be installed with inter-

nal or external sensing. Unless otherwise

speciﬁ ed, the regulator is supplied by factory

with internal sensing. The regulator may be

con vert ed in the ﬁ eld to external sensing (see

Section VII Maintenance, Paragraph H).

b. Reference DAG-TB, Table DAG-11 for recom-

mendations for applying external pressure

sensing.

c. For internal sensing, no external line is re-

quired. For external sensing, use an external

control line. The line is connected from the port

(1/4" NPT) on the side of the body di a phragm

ﬂ ange (see port 5 in Fig. 5) to a pres sure tap

10 to 15 pipe diameters downstream of the

reg u la tor. Use 1/4" or 3/8" outer di am e ter

tubing or 3/8" (DN10) pipe hav ing an inner

di am e ter equiv a lent to schedule 40 pipe.

d. 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,

SECTION III

SECTION II

For welded installations, all internal trim parts, seals

and diaphragm(s) must be removed from reg u la tor

body prior to welding into pipeline. The heat of

fusion welding will dam age non-metallic parts if

not re moved. NOTE: This does not apply to units

equipped with extended pipe nip ples.

CAUTION A

1. Regulator may be rotated around pipe axis 360

degrees. For ease of maintenance, the recom-

mended position is with the spring chamber (4)

upwards. In liquid service it is recommended that

the spring cham ber (4) be oriented downwards, and

that a cus tom er supplied and installed vent valve

be pro vid ed at the external sensing con nec tion to

bleed-off trapped gas/air under the di a phragm.

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

Summary of content (16 pages)

PAGE 1
INSTALLATION, OPERATION & MAINTENANCE MANUAL (IOM) IOM-DA1 11-13 MODEL DA1 DA1 - DIRECT-ACTING, SPRING LOADED PRESSURE REDUCING REGULATOR SECTION I I. DESCRIPTION AND SCOPE The Model DA1 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). With proper trim utilization, the unit is suitable for liquid, gaseous, or steam service.
PAGE 2
which allows the diaphragm chamber to always be self draining. The external sensing line may be sloped upward for liquids or gases. CAUTION C Installation of adequate overpressure protection is recommended to protect the regulator from overpressure and all downstream equipment from damage in the event of regulator failure. Supply @ P1 CAUTION B DO NOT HYDROSTATIC TEST THROUGH AN INSTALLED UNIT; ISOLATE REGULATOR FROM TEST.
PAGE 3
9. Develop system flow to a level near its expected normal rate, and reset the regulator set point by turning the adjusting screw CW to increase outlet pressure, or CCW to reduce outlet pressure. from the set point of Step 9. The maximum rise in outlet pressure on decreasing flow should not exceed the stated upper value of the range spring by greater than 10%. If it does, consult factory. 10. Reduce system flow to a minimum level and observe pressure set point. Outlet pressure will rise SECTION VI VI.
PAGE 4
13 13 13 19 27.2 27.2 19 19 BODY 27.1 27.1 16 27.4 20 20 17.1 20 Type OR — O-Ring Dynamic Seal Type CP— TFE Cap Dynamic Seal Type CW — TFE Cap Dynamic Seal + Wiper 13 13 13 19 19 19 27.6 27.5 27.5 27.3 16 Type PR — PRA Dynamic Seal 17.3 17.1 20 19 27.5 20 Type PW — PRA Dynamic Seal + Wiper 20 Type UC — U-Cup Dynamic Seal 27.
PAGE 5
B. Main Valve Disassembly: WARNING 1 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. 1. Shut down the system in accordance with Section VI. 2. Disconnect the external sensing line, if installed. 3. Though it is possible to disassemble the valve unit while installed in a pipeline, it is recommended that maintenance be done in a shop when possible.
PAGE 6
c. d. e. f. g. h. from the upper end of the cage (19). Remove o-ring middle stem seal (14.2) from piston-guide bearing (13). Examine the components (27.1, 27.2, 27.3, 27.4, 27.5, 27.6) of the dynamic side seal (27) mechanism to determine if significant leakage was occurring. If the dynamic side seal (27) shows signs of significant leakage, determine if operating conditions are exceeding pressure, pressure drop, or temperature limits. Remove dynamic side seal (27) components.
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3. QC Requirements: a. Valve plug (20); 1. 16 rms finish on its seating surface for tight shutoff. 2. No major defects on bottom guide spindle. b. Cage (19); 1. 16 rms finish on cylinder bore. No “ledges” formed due to wear from moving dynamic side seal (27) or wiper seal (16). c. Lower guide bushing (24) (non-replaceable): 1. 16 rms finish on bore. 2. Max 0.015 inch (0.38 mm) clearance between valve plug (20) spindle and lower guide bushing (24). d. Internal sensing drilled plug (32); 1.
PAGE 8
4. Position piston-guide bearing (13) over and into upper end of cage (19) until the cap seal (27.1) edge touches the upper lip of the cage (19). While gently applying force to press the piston-guide bushing (13) into the cage (19), simultaneously use fingers to lightly press the cap seal (27.1) inwards into the groove of the piston-guide bearing (13) until the cap seal (27.1) “slips into” the cage (19). DO NOT USE TOOLS, LUBRICANT, OR HEAVY FORCE TO ENGAGE THE CAP SEAL (27.1) INTO THE CAGE (19).
PAGE 9
e. Type PW: 1. Place wiper washer (17.1) into “cup” of Wiper Seal (16). Holding these parts (17.1 & 16) between thumb and forefinger, insert into cage (19) at an approximate 45° angled approach with wiper washer (17.1) on bottom, wiper seal (16) on top with turneddown lip of wiper seal (16) entering cage (19) first. Rotate wiper seal (16) and wiper washer (17.1) to a level position approximately half way down into cage (19). Allow wiper washer (17.1) to rest on bottom of cage (19). 2.
PAGE 10
values. DO NOT ALLOW PLUG (20) TO ROTATE AGAINST SEAT RING (21) DURING TIGHTENING. Recommended Torque Values are: Body Size Torque in. (mm) ft-lbs (Nm) 1/2"-1" (DN15-25) 30-50 (41-68) 1 1/4"-2" (DN32-50) 45-70 (61-95) e. This completes ITA reassembly. F. Main Reassembly: 1. Place body (23) in a vise. 2. Reinstall internal sensing drilled plug (32) with compatible thread sealant. 3. Insert the lower piston spring (22) into the body (23), if supplied. 4.
PAGE 11
9. Metal Diaphragm Designs: a. Install new diaphragm gasket (37) onto body (23) diaphragm flange. b. Position diaphragm(s) (9) onto body's (23) diaphragm flange with bolt holes aligned. c. Position upper diaphragm pressure plate (8) onto center top of diaphragm(s) (9) with hub upwards. 10. Place a small amount of heavy grease into the adjusting screw (1) threaded opening of spring chamber (4). Reengage both adjusting screw (1) and its lock nut (2) with spring chamber (4).
PAGE 12
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. 3. Pressure Containment Test. a. Pressurize inlet and outlet to 1.0 x Upper Value of Range Spring or 30 psig (2.1 Barg) with air or GN2, whichever is higher. b. Soap solution test all external leak points; plugged connections, diaphragm flange, diaphragm bolting and spring chamber vent opening. 4.
PAGE 13
3. Downstream pressure will not reach desired setting. Possible Causes A. Supply pressure is down (confirm on pressure gauge.) B. Undersized regulator. Remedies A. Increase supply pressure. B. Check actual flow conditions; resize regulator for minimum and maximum flow; if necessary, replace with larger regulator. 4. Diaphragm continually breaks (steam service regulators). Possible Causes Remedies A. Stem seals (14) which protect fluorocarbon elastomer A. replace with new stem seals (14).
PAGE 14
SECTION IX IX. 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 15
2 4 1 5 6 7 13 8 11 32 33 9 10 14.1 12 18 15 14.2 27 19 16 21 17.1 20 24 14.3 Model DA1 Composition Diaphragm (w/Wiper Seal) Item No. 1 2 4 5 6 7 8 9 9.1 9.2 9.9 10 11 * 12 13 14 14.1 14.2 14.
PAGE 16
2 1 5 4 6 8 11 9 13 37 32 33 12 27 18 15 19 21 22 23 17.2 24 20 Model DA1 Metal Diaphragm (wo/Wiper Seal) Item No. 1 2 4 5 6 8 9 11 * 12 13 15 17.2 18 19 20 21 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.