cashco 5381 Instruction manual

INSTALLATION, OPERATION & MAINTENANCE MANUAL (IOM) IOM-5381
02-20
MODEL 5381
PRESSURE REDUCING SANITARY REGULATOR
SECTION I
Model 5381 is a pressure reducing regulator used to control downstream (outlet or P2) pressure. Inlet and outlet
size is 1/2" (DN15) with Tri-Clamp®connections. The 5381 incorporates a stainless steel body. Refer to Technical
Bulletin 5381-TB for specific design conditions and selection recommendations.
I. DESCRIPTION AND SCOPE
II. INSTALLATION
1. An inlet block valve should always be installed
upstream of the regulator.
2. If service application is continuous such that
shutdown is not readily accomplished, it is rec-
ommended that an inlet block valve, outlet block
valve, and a manual bypass valve be installed.
The maximum outlet pressure is listed on the
nameplate as the upper range spring pressure
level, and is the recommended “upper operative
limit” for the sensing diaphragm (see Section IV.
Startup, Step 7). Higher pressures could damage
the diaphragm. (Field hydrostatic tests frequently
destroy diaphragms. DO NOT HYDROSTATIC TEST
THROUGH AN INSTALLED UNIT; ISOLATE FROM
TEST.)
Recommended Piping Schematic
For Pressure Reducing Station
3. An outlet pressure gauge should be located
approximately ten pipe diameters downstream, and
within sight.
4. All installations should include a downstream relief
device if the inlet pressure could exceed the pressure
rating of any downstream equipment or the maximum
outlet pressure rating of the unit.
5. Flow Direction: Install so the flow direction matches
the arrow stamped on the regulator body.
6. Install in well drained horizontal pipe, properly trapped
with spring chamber (2) in the vertical position to allow
for proper draining.
SECTION II
CAUTION
Installation of adequate overpressure protection
is recommended to protect the regulator and
all downstream equipment from damage in the
event of regulator failure.
CAUTION
Supply
@ P1
Model
5381
Outlet
@ P2
SRV
Bypass
Blowdown-Drain
Blowdown-Drain
P1
ISO Registered Company

2IOM-5381
SECTION III
III. PRINCIPLE OF OPERATION
1. Movement occurs as pressure variations register
on the diaphragm. The registering pressure is
the outlet, P2, or downstream pressure. The
range spring opposes diaphragm movement. As
outlet pressure drops, the range spring pushes
the diaphragm down, opening the port; as outlet
pressure increases, the diaphragm pushes up
and the port opening closes.
2. A complete diaphragm failure will cause the
regulator to fail open.
SECTION IV
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.
2. Relax the range spring by turning the adjusting
knob (30) counter clockwise (CCW) a minimum of
three (3) full revolutions. This reduces the outlet
(downstream) pressure set point.
3. If it is a “hot” piping system and equipped with
a bypass valve, slowly open the bypass valve
to pre-heat the system piping and to allow slow
expansion of the piping. Assure proper steam
trap operation if installed. Closely monitor outlet
(downstream) pressure via gauge to assure not
over-pressurizing. NOTE: If no bypass valve is
installed, extra caution should be used in starting
up a cold system; i.e. do everything slowly.
4. Crack open the outlet (downstream) block valve.
5. Slowly open the inlet (upstream) block valve
observing the outlet (downstream) pressure
gauge. Determine if the regulator is flowing. If
not, slowly rotate the regulator's adjusting knob
clockwise (CW) until flow begins.
6. Continue to slowly open the inlet (upstream)
block valve until fully open.
7. Continue to slowly open the outlet (downstream)
block valve, especially when the downstream
piping system isn't pressurized. If the outlet
(downstream) pressure exceeds the desired
pressure, close the block valve and go to Step
2, then return to Step 4.
8. When flow is established steady enough that the
outlet (downstream) block valve is fully open,
begin to slowly close the bypass valve if installed.
9. Develop system flow to a level near its expected
normal rate, and reset the regulator set point by
turning the adjusting knob CW to increase outlet
pressure, or CCW to reduce outlet pressure.
10. Reduce system flow to a minimum level and
observe set point. Outlet pressure will rise from
the set point of Step 9. The maximum rise in
outlet pressure on decreasing flow should not
exceed the stated upper limit of the range spring
by greater than 10%; i.e. 20-80 psig (1.38-5.52
Barg) range spring, at low flow the outlet pressure
should not exceed 88 psig (6.07 Barg), if it does,
consult factory.
IV. STARTUP
1. On systems with a bypass valve, and where
system pressure is to be maintained as the
regulator is shut down, slowly open the bypass
valve while closing the inlet (upstream) block
valve. Fully close the inlet (upstream) block valve.
(When on bypass, the system pressure must be
constantly observed and manually regulated.
Close the outlet (downstream) block valve.
V. SHUTDOWN
SECTION V
2. If the regulator and system are to both be shut
down, slowly close the inlet (upstream) block
valve. Close the outlet (downstream) valve only
if regulator removal is required.
Do not walk away and leave a bypassed
regulator unattended.
CAUTION

IOM-5381 3
VI. MAINTENANCE
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.
To prevent damage to body, use lead jaws when
clamping body in a vise. Position body so that vise
does not close over inlet and outlet connections.
1. Securely install the body (1) in a vise with
the spring chamber (2) oriented upwards.
A. General:
1. Maintenance procedures hereinafter are
based upon removal of the regulator unit
from the pipeline where installed.
2. Ownershouldrefertoowner'sprocedures
for removal, handling, cleaning and
disposal of nonreusable parts, i.e.
gaskets, etc.
3. Refer to Figure 2 for basic regulator, item
number reference ( ).
B. Diaphragm Replacement:
SPRING UNDER COMPRESSION. Prior to removing
spring chamber, relieve spring compression by
backing out the adjusting knob. Failure to do so
may result in flying parts that could cause personal
injury.
2. Relax range spring (17) by turning
adjusting knob (30) CCW until removed
from spring chamber (2).
3. Loosen spring chamber (2) by placing
wrench on “flats” and rotating CCW
making sure not to use the flat where the
vent hole is located.
4. Remove spring chamber (2), range spring
(17) and spring button (5).
11. For metal diaphragm(s) (13), place
diaphragm gasket (14) into body
recess (none required for composition
diaphragm). Set diaphragm subassembly
into the body.
Sizes Diaphragm Torque Value
ALL Metal 60 in/lbs. (6.8 Nm)
Composition 15 in/lbs. (1.7 Nm)
6. Loosen pressure plate nut (10) and
separate all parts (3, 4, 9, 13 & 15) of the
diaphragm subassembly.
7. Inspect pressure plate (3) to assure no
deformation due to over-pressurization.
If deformed, replace.
8. Remove diaphragm gasket (14). (If a
composition diaphragm is used there is
no diaphragm gasket (14).
9. Clean inside body surfaces in accordance
with Owner's cleaning procedures. Do
not scratch diaphragm O-ring seating
surface NOTE: Maintenance must
include a level of cleanliness equal to
Cashco cleaning standard #S-1576.
Contact factory for details.
10. Reassemble diaphragm subassembly
by placing pusher plate O-ring (15),
diaphragm(s) (13), pressure plate (3)
and lock washer (9) over the threaded
post of pusher plate (4). Assure the
pressure plate (3) is placed with curved
outer rim down next to the diaphragm (13)
surface. Tighten pusher plate nut (4) to
the following torque values:
5. Remove the diaphragm subassembly
consisting of the pressure plate nut
(10), lock washer (9), pressure plate (3),
diaphragm (13), pusher plate O-ring (15)
and pusher plate (4). NOTE: Refer to the
quantity of diaphragms (13) incorporated
per the bill of materials listing. Depending
on outlet pressure level, multiple metal
diaphragms may be “stacked”.
Figure 1: Diaphragm Subassembly
SECTION VI
WARNING
CAUTION
WARNING
13
910
3
15 4

4IOM-5381
12. Place the range spring (17) over the pressure
plate nut (10) of the diaphragm subassembly.
13. Apply a small amount of process compatible
anti-seeze into depression of spring button (5)
where adjusting screw (8) bears. Set spring
button (5) onto range spring (17); ensure spring
button (5) is laying flat on top of the spring.
14. Inspect body (1) and spring chamber (2)
threads for debris. NOTE: Apply a small
amount of process compatible anti-seeze to
spring chamber (2) threads to prevent galling.
Rotate the spring chamber (2) CW by hand into
the threaded portion of the body (1) ensuring to
not cross thread. Tighten spring chamber (2) to
body (1) connection to a 30–35 Ft-lbs (41–47
Nm) torque value.
15. Reinstall adjusting knob (30) with locknut (11)
into the spring chamber (2).
16. Pressurize with air and spray liquid leak
detector to test around body (1) and spring
chamber (2) for leakage. Ensure that an outlet
pressure is maintained during this leak test of
at least mid-range spring level; i.e. 20-80 psig
(1.4–5.5 Barg) range spring, 50 psig (3.4 Barg)
test pressure minimum.
C. Trim Replacement
NOTE: When piston (15) assemblies are
used with comp seats, Cashco, Inc. does
not recommend attempting to remove the
comp seat. If composition seat is damaged,
replace entire piston assembly.
4. Clean flat mating surfaces of body (1) to body
cap (6) shoulder. Be careful not to scratch
either surface.
5. Clean debris from within the body (1) cavity.
Clean all parts to be reused according to
owner's procedures. NOTE: Maintenance
must include a level of cleanliness equal
to Cashco cleaning standard #S-1576.
Contact factory for details.
6. Place the piston (16), stem first, into the
body cap (6) cavity.
7. Place piston spring (7) over spring hub of the
piston (16).
8. Place o-ring (29) in body cap (6).
9. Apply a small amount of process compatible
anti-seeze to the body cap (6) threads.
Thread body cap (6) into body (1). Impact
until body cap is metal to metal against body.
10. Bench test unit for suitable operation.
NOTE: Regulators are not tight shutoff
devices. Even if pressure builds up beyond
set point, a regulator may or may not develop
bubble tight shutoff. In general, tighter
shutoff can be expected with composition
seat.
11. Pressurize with air and spray liquid leak
detector to test around body cap (6) and
body (1) for leakage. Test pressure should
be a minimum of 100 psig (6.9 Barg) at the
inlet.
1. Secure body (1) in a vise with the body cap
(6) oriented up and the spring chamber (2)
directed downwards.
2. Remove body cap (6) by rotating CCW.
Remove o-ring (29).
3. Remove piston spring (7) and piston (16).
Note: The seat and piston (16) guide are
integral parts of the body (1) casting. Inspect
integral seat and parts for excessive wear,
especially at seating surfaces. Replace if
worn, nicked or depressed. If integral seat
is nicked, use seat lapping compound to
remove.
To prevent damage to body, use soft jaws when
clamping body in a vise. Position body so that vise
does not close over inlet and outlet connections.
CAUTION

IOM-5381 5
SECTION VII
VII. TROUBLE SHOOTING GUIDE
1. Erratic operation; chattering.
Possible Causes Remedies
A. Oversized regulator; inadequate rangeability. A1. Check actual flow conditions, re-size regulator for minimum and
maximum flow.
A2. Increase flow rate.
A3. Decrease regulator pressure drop; decrease inlet pressure by
placing a throttling orifice in inlet piping union.
A4. Install next step higher range spring. Contact factory.
A5. Before replacing regulator, contact factory.
B. Worn piston; inadequate guiding. B. Replace trim ( possible body replacement).
C. Weakened/broken piston spring. C. Replace piston spring. Determine if corrosion is causing the
failure.
2. Regulator can't pass sufficient flow.
Possible Causes Remedies
A. Regulator undersized. A1. Confirm by opening bypass valve together with regulator.
A2. Check actual flow conditions, re-size regulator; if regulator has
inadequate capacity, consult factory.
B. Incorrect range spring (screwing in CW of adjusting screw does
not allow bringing pressure level up to proper level).
B. Replace range spring with proper higher range. Contact factory.
C. Too much droop. C1. Review droop expected.
C2. Contact factory.
3. Leakage through the spring chamber vent hole.
Possible Causes Remedies
A. Normal-life diaphragm failure. A. Replace diaphragm.
B. Abnormal short-life diaphragm failure. B1. Can be caused by excessive chattering. See No. 1. to remedy
chatter.
B2. Can be caused by corrosive action. Consider alternate diaphragm
material.
B3. For composition diaphragms, assure not subjecting to over-tem-
perature conditions.
B4. Downstream (outlet) pressure buildup occurring that overstresses
diaphragms. Relocate regulator or protect with safety relief valve.
C. O-ring failure. C. Replace O-ring (15), apply appropriate torque.
4. Sluggish operation.
Possible Causes Remedies
A. Fluid too viscous. A. Heat fluid. Contact factory.
5. Excessive pressure downstream.
Possible Causes Remedies
A. Regulator not closing tightly. A. 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 trim.
B. Downstream block. B. Check system; isolate (block) flow at regulator inlet - not outlet.
Relocate regulator if necessary.
C. No pressure relief protection. C. Install safety relief valve, or rupture disc.
D. Restricted diaphragm movement. D. Assure no moisture in spring chamber at temperatures below
freeze point. Assure no dust or debris entering vent opening. If
rainwater or debris can enter, re-orient regulator.

6IOM-5381
SECTION VIII
NEW REPLACEMENT UNIT:
Contact your local Cashco, Inc., Sales
Representative with the Serial Number and Product
code. With this information they can provide a
quotation for a new unit including a complete
description, price and availability.
–7–
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).
Product Code typical format as follows: (last digit is alpha character that reflects revision level for the product).
PARTS "KIT" for FIELD REPAIR:
Contact your local Cashco, Inc., Sales
Representative with the Serial Number and Product
code. Identify the parts and the quantity required
to repair the unit from the "BOM" sheet that was
provided when unit was originally shipped.
NOTE: Those part numbers that have a quantity indicated
under "Spare Parts" in column "A” reflect minimum
parts required for inspection and rebuild, - "Soft
Goods Kit". Those in column “B” include minimum
trim replacement parts needed plus those "Soft
Goods" parts from column "A".
If the "BOM" is not available, refer to the cross-
sectional drawings included in this manual for part
identification and selection.
A Local Sales Representative will provide quotation
for appropriate Kit Number, Price and Availability.
CAUTION
Do not attempt to alter the original construction
of any unit without assistance and approval from
the factory. All purposed changes will require a
new name plate with appropriate ratings and new
product code to accommodate the recommended
part(s) changes.
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. does not assume responsibility for the selection, use or maintenance of any product. Responsibility for proper selection, use and maintenance of any
Cashco, Inc. product remains solely with the purchaser.

IOM-5381 7
Figure 2: Basic Model 5381, Metal Seat Design
Item No. Description Repair Kit B
1 Body
2 Spring Chamber
3 Pressure Plate
4 Pusher Plate
5 Spring Button
6 Body Cap
7 Piston Spring ----------------------- ‡‡
8 Adjusting Screw
9 Lock Washer
10 Pressure Plate Nut
Item No. Description Repair Kit B
11 Adjusting Screw Locknut
13 Diaphragm(s) ----------------------- ‡‡
14 Diaphragm Gasket ---------------- ‡‡
15 Pusher Plate O-ring---------------- ‡‡
16 Piston & Piston Subassy.-------- ‡‡
17 Range Spring
29 Body Cap O-ring -------------------- ‡‡
30 Adjusting Knob
‡‡ Recommended Spare Part

8IOM-5381
Cashco, Inc. declares that the products listed in the table below has been found to comply with the Essential
Health and Safety Requirements relating to the design and construction of products intended for use in potentially
explosive atmospheres given in Annex II of the ATEX Directive 2014/34/EU. Compliance with the Essential
Health and Safety Requirements has been assured by compliance with EN ISO 80079-36:2016 and EN ISO
80079-37:2016. The product will be marked as follows:
II 2 G
Ex h IIB T6... T1 Gb
1000ATEXR1 X
The ‘X’ placed after the technical file number indicates that the product is subject to specific conditions of use as
follows:
1. The maximum surface temperature depends entirely on the operating conditions and not the equipment
itself. The combination of the maximum ambient and the maximum process medium temperature shall
be used to determine the maximum surface temperature and corresponding temperature classification,
considering the safety margins described prescribed in EN ISO 80079-36:2016, Clause 8.2. Additionally, the
system designer and users must take precautions to prevent rapid system pressurization which may raise
the surface temperature of system components and tubing due to adiabatic compression of the system gas.
Furthermore, the Joule-Thomson effect may cause process gases to rise in temperature as they expand
going through a regulator. This could raise the external surface temperature of the regulator body and
the downstream piping creating a potential source of ignition. Whether the Joule-Thomson effect leads to
heating or cooling of the process gas depends on the process gas and the inlet and outlet pressures. The
system designer is responsible for determining whether the process gas temperature may raise under any
operating conditions.
2. Where the process medium is a liquid or semi-solid material with a surface resistance in excess of 1GΩ,
special precautions shall be taken to ensure the process does not generate electrostatic discharge.
3. Special consideration shall be made regarding the filtration of the process medium if there is a potential for
the process medium to contain solid particles. Where particles are present, the process flow shall be <1m/s
(<3.3 ft/s) in order to prevent friction between the process medium and internal surfaces.
4. Effective earthing (grounding) of the product shall be ensured during installation.
5. The valve body/housing shall be regularly cleaned to prevent build up of dust deposits.
6. Regulators must be ordered with the non-relieving option (instead of the self-relieving option) if the process
gas they are to be used with is hazardous (flammable, toxic, etc.). The self-relieving option vents process
gas through the regulator cap directly into the atmosphere while the non-relieving option does not. Using
regulators with the self-relieving option in a flammable gas system could create an explosive atmosphere in
the vicinity of the regulator.
7. Tied diaphragm regulators with outlet ranges greater than 7 barg (100 psig) should be preset to minimize the
risk that improper operation might lead to an outboard leak and a potentially explosive atmosphere.
8. All equipment must only be fitted with manufacturer’s original spare parts.
9. Ensure that only non-sparking tools are used, as per EN 1127-1, Annex A.
ATEX 2014/34/EU: Explosive Atmospheres and Cashco Inc. Products

IOM-5381 9
Cashco, Inc.
P.O. Box 6
Ellsworth, KS 67439-0006
PH [phone]
Fax. # [phone]
www.cashco.com
email: [email protected]
Printed in U.S.A. IOM-5381
Cashco do Brasil, Ltda.
Al.Venus, 340
Indaiatuba - Sao Paulo, Brazil
PH [phone]
Fax. No.
www.cashco.com
email: [email protected]
Cashco GmbH
Handwerkerstrasse 15
15366 Hoppegarten, Germany
PH [phone]
Fax. No. [phone]
www.cashco.com
email: [email protected]
REGULATORS
PRODUCT
31-B, 31-N
1164, 1164(OPT-45)
1171, 1171(OPT-45), 1171(CRYO)
2171, 2171(OPT-45), 2171(CRYO), 3171
1465, 3381, 3381(OPT-45), 3381(OPT-40)
4381, 4381(OPT-37), 4381(CRYO), 4381(OPT-45), 5381
MPRV-H, MPRV-L
PBE, PBE-L, PBE-H
CA-1, CA-2
CA1, SA1, CA4, SA4, CA5, SA5
DA2, DA4, DA5, DA6, DA8
DA0, DA1, DAP, SAP
SLR-1, SLR-2, PTR-1
ALR-1, ULR-1, PGR-1
BQ, BQ(OPT-45), BQ(CRYO)
123, 123(CRYO), 123(OPT-45), 123(OPT-46G)
123-1+6, 123-1+6(OPT-45), 123-1+6(OPT-46G), 123-1+6+S, 123-1+6+S(OPT-40)
1000HP, 1000HP(OPT-37), 1000HP(OPT-45), 1000HP(OPT-45G), 1000HP(CRYO)
1000HP-1+6, 1000HP-1+8, 1000LP, 1000LP(OPT-45), 1000LP(OPT-46G)
6987
8310HP, 8310HP-1+6, 8310HP-1+8, 8310LP, 8311HP, 8311LP
345, 345(OPT-45)
BA1/BL1, PA1/PL1
C-BPV, C-PRV, C-CS
D, D(CRYO), D(OPT-37), D(OPT-20), D(OPT-45)
DL, DL(LCC), DL(OPT-45)
BR, BR(CRYO)
HP, HP(LCC), HP(OPT-45), HP(OPT46G), HP-1+6+S(OPT-40), HP-1+6+S
P1, P2, P3, P4, P5, P7
B2, B7
POSR-1, POSR-2
5200P, 5300P
135
NW-PL, NW-SO
CG-PILOT
FG1
CONTROL
VALVES
RANGER, 987, PREMIER
964, 521, 988, 988-MB, 989
2296/2296HF
SCV-30, SCV-S
FL800/FL200
TANK
BLANKETING
8700, 8910, 8920, 8930, 8940
2100, 2199
3100, 3200, 3300, 3400, 3500, 3600, 3700
1078, 1088, 1100, 1049
5100, 5200, 5400 ,5500
4100, 4200, 4300, 4400, 4500, 4600
MISC 764P/PD, 764-37, 764T