INSTALLATION, OPERATION & MAINTENANCE MANUAL IOM-1000HP- Basic 02-20 ISO Registered Company MODEL 1000HP - BASIC PRESSURE REDUCING REGULATOR SECTION I I. DESCRIPTION AND SCOPE The Model 1000HP is a pressure reducing regulator used to control downstream (outlet or P2) pressure to levels between 10 and 300 psig (0.7-20.6 Barg). Sizes are 1/2", 3/4", 1", 1-1/4", 1-1/2" and 2" (DN15, 20, 25, 32, 40 and 50). The unit is designed for liquid, gaseous or steam service with proper trim utilization, and proper jet selection. Refer to Technical Bulletin 1000HP-TB for sizing, application and selection recommendations. Installation, operation and maintenance manuals (IOM's) also exist for the following other Model 1000 products: 1000LP-Basic 1000HP-Differential 1000HP-Cryogenic SECTION II CAUTION CAUTION For welded installations, all internal trim parts, Installation of adequate overpressure protection seals and diaphragm(s) must be removed from is recommended to protect the regulator from regulator body prior to welding into pipeline. The overpressure and all downstream equipment from heat of fusion welding will damage non-metallic damage in the event of regulator failure. parts if not removed. NOTE: This does not apply to units equipped with extended pipe nipples. II. INSTALLATION 1. An inlet block valve should always be installed. An outlet block valve is recommended. 2. If service application is continuous such that shut down is not readily accomplished, it is rec om mended that an inlet block valve and a man u al bypass valve be installed. 3. Pipe unions must be installed to allow removal Recommended Piping Schematic from piping. Trim can only be changed by unit For Pressure Reducing Station removal from pipeline. If flanges are utilized, a lap joint flange is required on the inlet end of the CAUTION regulator to help align bolt holes as the cylinder screws into place. The maximum outlet pressure listed on the name plate is the “upper operative limit” for the 4. An outlet pressure gauge should be located sens ing dia phragm. Higher pres sures could ap prox i mate ly ten pipe diameters down stream, damage the di a phragm. (Field hydro static and with in sight. tests fre quent ly de stroy dia phragms. DO NOT HY DRO STAT IC TEST THROUGH AN IN STALLED 5. All installations should include a downstream UNIT; ISOLATE FROM TEST.) relief de vice if the inlet pressure could exceed the 6. Clean the pip ing of all foreign material in clud ing pressure rating of any downstream equip ment or chips, welding scale, oil, grease and dirt the maximum outlet pressure rating of the unit. before installing the regulator. Strainers are rec om mended. 7. In placing thread sealant on pipe ends prior to with spring cham ber ver ti cal upwards. Orient en gage ment, ensure that excess material is to pre vent the spring cham ber vent hole from re moved and not allowed to enter the regulator col lect ing rain wa ter or debris. upon startup. 11. Regulators are not to be direct buried under- 8. Flow Direction: Install so the flow direction ground. match es the arrow cast on the body. 12. For insulated piping systems, recommen dation is 9. For best performance, install in well drained to not insulate regulator. hor i zon tal pipe, properly trapped if a steam ser vice application. 13. Cashco does not recommend field welding on the cyl in der (inlet) end of the body due to the 10. Basic regulator may be rotated around the pipe pos si bil i ty of warpage. axis 360° , and may be installed in a horizontal or vertical pipe line. Rec om mend ed po si tion is SECTION III III. PRINCIPLE OF OPERATION setting is capable for a given inlet P1 pressure. This is a function of the ratio of the port area to 1. The Model 1000 is available in two variations: diaphragm area. It is possible for there to be too 1000LP (larger diaphragm) for downstream pres- high of an inlet pressure for the regulator to close sure control from 1-30 psig (0.07-2.06 Barg); off against. (Refer to 1000-TB, Tables 9 through 1000HP (small er diaphragm) for down stream 12 for limits.) Reduced ports, Option 1000-12, pressure control from 10-300 psig (0.7-20.6 allow lower down stream (P2 or outlet) pressure Barg), body size dependent. settings for a given up stream (P1 or inlet) pres sure level. 2. Movement occurs as pressure variations reg- ister on the diaphragm. The registering pres sure 5. The FTO design also is limited by a minimum is the outlet, P2, or downstream pressure. The pres sure drop. If the pressure drop is below 5 range spring opposes di a phragm move ment. As psid, an Option 1000-17 piston spring should be out let pressure drops, the range spring push es utilized to assist open ing the piston. the diaph ragm down, opening the port; as outlet pressure increases, the dia phragm pushes up 6. The Model 1000 includes an aspiration jet ef fect, and the port closes. due to the clearance of the piston from the body near the outlet. These clear ances vary as to 3. The Model 1000 includes a rocker arm in its whether the fluid is a gas (including steam), a op er a tion al mechanism. The rocker arm allows liquid, or a viscous liquid (requires Option 1000- the regulator to operate flow-to-open (FTO), 27). Jets must be selec ted to match one of these rather than conventional flow-to-close (FTC), three general fluids. An improper jet selection will which increases rangeability. reduce perfor mance. 4. Due to the FTO design, there is a limit as to how 7. A complete diaphragm failure will cause the low of a downstream (P2 or outlet) pressure level regulator to fail open. SECTION IV IV. STARTUP 1. Start with the block valves closed. A bypass 3. If it is a “hot” piping system, and equipped with valve may be used to maintain outlet pressure a bypass valve, slowly open the bypass valve in the downstream system without changing the to pre-heat the system piping and to allow slow fol low ing steps. expansion of the piping. Ensure proper steam trap operation if installed. Closely monitor out let 2. Relax the range spring by turning the adjusting (downstream) pressure via gauge to ensure not screw counterclockwise (CCW) a min i mum of over-pressurizing. NOTE: If no bypass valve is three (3) full revolutions. This re duces the outlet installed, extra caution should be used in start ing (down stream) pres sure set point. up a cold system; i.e. do everything slowly. 2 IOM-1000HP-Basic 4. Crack open the outlet (downstream) block valve. 8. When flow is established steady enough that the outlet (downstream) block valve is fully open, 5. Slowly open the inlet (upstream) block valve begin to slowly close the bypass valve if in stalled. ob serv ing the outlet (downstream) pressure gauge. Determine if the regulator is flowing. If 9. Develop system flow to a level near its expected not, slowly rotate the regulator adjusting screw normal rate, and reset the regulator set point by clockwise (CW) until flow begins. turning the adjusting screw CW to increase outlet pressure, or CCW to reduce outlet pres sure. 6. Continue to slowly open the inlet (upstream) block valve until fully open. 10. Reduce system flow to a minimum level and ob serve set point. Outlet pressure will rise from 7. Continue to slowly open the outlet (down stream) the set point of Step 9. The maximum rise in block valve, especially when the down stream outlet pressure on de creas ing flow should not piping system isn't pres surized. If the outlet exceed the stated upper limit of the range spring (downstream) pressure exceeds the de sired by greater than 30%; i.e. 10–40 psig (0.7-2.75 pres sure, close the block valve and go to Step 2, Barg) range spring, at low flow the outlet pres sure then return to Step 4. should not exceed 52 psig (3.6 Barg). If it does, consult factory. SECTION V V. SHUTDOWN CAUTION 1. On systems with a bypass valve, and where sys tem pressure is to be maintained as the Do not walk away and leave a bypassed regulator regulator is shut down, slowly open the bypass un at tend ed. valve while closing the inlet (up stream) block valve. Fully close the inlet (up stream) block valve. 2. If the regulator and system are to both be (When on bypass, the system pressure must be shut down, slowly close the inlet (upstream) block constantly observed and manually reg u lat ed.) valve. Close the outlet (downstream) valve only Close the outlet (downstream) block valve. if reg u la tor removal is required. SECTION VI VI. MAINTENANCE 4. Regulators originally supplied as “oxygen cleaned” (Options 1000-55) are assembled using special gasket sealant, Fluorolube WARNING GR-362 1, or equivalent. Cashco, Inc. SYSTEM UNDER PRESSURE. Prior to perform ing rec om mends following factory cleaning spec- any maintenance, isolate the regulator from the ification #S-1134, or equiv a lent. Con tact system and relieve all pressure. Failure to do so factory for details. could result in personal injury. B. Diaphragm Replacement: A. General: 1. Securely install the body (1) in a vise with the 1. Maintenance pro ce dures hereinafter are spring chamber (2) directed up wards. based upon removal of the unit from the pipeline where in stalled.