Manual

ManualsBrandsCashco ManualsSensorsSAP

INSTALLATION, OPERATION & MAINTENANCE MANUAL (IOM)

IOM-SAP

11-13

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

MODEL SAP

ULTRA HIGH PURITY, PRESSURE LOADED

PRESSURE REDUCING REGULATOR

SECTION I

Refer to Technical Bulletin SAP-TB for tech ni cal

speciﬁ cations.

ABBREVIATIONS

CCW – Counter Clockwise

CW – Clockwise

ITA – Inner Trim Assembly

SECTION III

SECTION II

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.

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.

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.

CAUTION

DO NOT HYDROSTATIC TEST THROUGH AN

IN STALLED UNIT; ISOLATE REGULATOR FROM

TEST. The "Outlet" rating as printed on the name-

plate 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.

Recommended Piping Schematic

for Pressure Reducing Station

Summary of content (12 pages)

PAGE 1
INSTALLATION, OPERATION & MAINTENANCE MANUAL (IOM) IOM-SAP 11-13 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 Refer to Technical Bulletin SAP-TB for technical specifications.
PAGE 2
SECTION IV IV. PRINCIPLE OF OPERATION 1. When a loading pressure – PLoad – is applied to the top side of a guide bearing, the outlet controlled pressure – P2 – will balance at approximately .90 – .98 of the loading pressure - PL. (NOTE: Fluctuations in P1 – Inlet Pressure will cause a deviation in P2 – Outlet Pressure due to inverse sympathetic ratio effect.) 2. Movement occurs as pressure variations register on the guide bearing. The registering pressure is the outlet, P2, or downstream pressure.
PAGE 3
SECTION VII VII. MAINTENANCE A. General: 1. The regulator may be serviced without removing the regulator from pipeline. The regulator is designed with quick-change trim to simplify maintenance. 2. Record the nameplate information to requisition spare parts for the regulator. The information should include: Size, Product Code, and Serial Number. 3. Refer to Section IX for recommended spare parts. Only use original equipment parts supplied by Cashco/KM for rebuilding or repairing regulators. 4.
PAGE 4
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 flange 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.
PAGE 5
wear. Examine for signs of leakage. If seat ring or plug show signs of significant leakage, determine if operating conditions - pressure, pressure drop, or temperature exceed ddesign limits. Replace as necessary. 6. Remove spring (22) from within the body (23). 7. Remove seal (28) from body flange groove. 8. Clean all metal parts to be reused according to owner's procedures. NOTE: Regulators are originally supplied with a level of cleanliness equal to Cashco cleaning standard #S-1662.
PAGE 6
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.
PAGE 7
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 process may be causing difficulties. The key to efficient trouble shooting is information and communication.
PAGE 8
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 filter at inlet. B. Oversized regulator; plug operates directly next to seat. B. Check actual flow conditions; resize regulator for minimum and maximum flow; if necessary, replace with smaller regulator. * Excess seat leakage may be diagnosed when a failure of the dynamic side seal has occurred.
PAGE 9
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 specifications of such product at any time without notice. Cashco, Inc.
PAGE 10
Sizes 3/4" - 1" Figure 1: Dynamic Side Seals Item No. 4 11 12 13 15 * 17 18 19 20 21 * 22 23 24 10 Description Loading Chamber Flange Nuts Flange Bolts Guide Bearing Cage Seal Cage Washer Cage Cap Screw Cage Plug Seat Return Spring Body Bushing (3" & 4" sizes) Item No.
PAGE 11
Sizes 2" Sizes 3" & 4" IOM-SAP 11
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. SAP-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.