cashco P1 Instruction manual

INSTALLATION, OPERATION & MAINTENANCE MANUAL (IOM) IOM-P1
02-20
SECTION I
I. DESCRIPTION AND SCOPE
The Model P1 is a pressure reducing regulator used to control downstream (outlet or P2 ) pressure. Sizes are 1/4"
and 3/8" (DN8 and DN10) FNPT or 1/2" (DN15) with Tri-Clamp connections. The unit is suitable for gaseous or liquid
services. Refer to Technical Bulletin P1-TB for design conditions and selection recommendations.
SECTION II
II. INSTALLATION
MODEL P1
SINGLE STAGE
PRESSURE REDUCING REGULATOR
1. An inlet block valve should always be installed.
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.
3. Pipe unions should be installed to allow removal
from piping.
4. An outlet pressure gauge should be located ap-
proximately ten pipe diameters downstream, and
within sight.
5. All installations should include a downstream re-
lief device if the inlet pressure could exceed the
pressure rating of any downstream equipment or
the maximum outlet pressure rating of the unit.
6. Clean the piping of all foreign material including
chips, welding scale, oil, grease and dirt before
installing the regulator. Strainers are recom-
mended.
7. In placing thread sealant on pipe ends prior to
engagement, ensure that excess material is
CAUTION
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.
removed and not allowed to enter the regulator
upon startup.
8. Flow Direction: Install so the flow direction match-
es the inlet stamp on the main regulator body (1).
9. For best performance, install in well drained hori-
zontal pipe.
10. Basic Regulator - (Refer to Figure 2, Model P1):
Regulator may be rotated around the pipe axis
360°. Recommended position is with aluminum
knob (4) vertical upwards.
11. Regulators are not to be buried underground.
12. For insulated piping systems, recommendation is
to not insulate regulator.
Recommended Piping Schematic
For Pressure Reducing Station
P1
Outlet
@P2
SRV
Supply
@P1
Bypass
Model P1
Reducing
Regulator
Blowdown-Drain Blowdown-Drain
ISO Registered Company

IOM-P1
2
SECTION IV
IV. STARTUP
SECTION V
V. SHUTDOWN
SECTION III
III. PRINCIPLE OF OPERATION
1. Movement occurs as pressure variations register
on the diaphragm (7.1). The registering pressure
is the outlet, P2, or downstream pressure. The
range spring (15) opposes diaphragm move-
ment. As outlet pressure drops, the range spring
pushes the diaphragm (7.1) down, opening the
port; as outlet pressure increases, the diaphragm
(7.1) pushes up and the port opening closes.
2. A complete diaphragm (7.1) failure will cause the
regulator to fail open.
The maximum outlet pressure is stamped on the
body 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.)
CAUTION
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 (15) by turning knob (4)
counter clockwise (CCW) until rotation comes to
a complete stop.
3. If it is a “hot” piping system, and equipped with
a bypass valve, slowly open the bypass valve
to preheat the system piping and to allow slow
expansion of the piping. Closely monitor outlet
(downstream) pressure via gauge to ensure 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 ob-
serving the outlet (downstream) pressure gauge.
Determine if the regulator is flowing. If not, slowly
rotate knob (4) 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 pip-
ing system isn't pressurized. If the outlet (down-
stream) 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 knob (4) 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%. Example: with 2-100 psig
(.14-6.9 Barg) range spring at low flow the outlet
pressure should not exceed 110 psig (7.6 Barg),
if it does, consult factory.
Do not walk away and leave a bypassed
regulator unattended.
CAUTION
1. On systems with a bypass valve, and where sys-
tem 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.
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.

IOM-P1 3
SECTION VI
VI. MAINTENANCE
To prevent damage to body, use soft jaws when
placing body in a vise. Position so that vise closes
over the flats on lower end of body.
5
SPRING UNDER COMPRESSION. Prior to removing
spring chamber, relieve range spring compression
by turning knob (4) CCW until rotation comes to a
complete stop. Failure to do so may result in flying
parts that could cause personal injury.
WARNING
CAUTION
A. General:
1. Maintenance procedures hereinafter are
based upon removal of the regulator unit from
the pipeline where installed.
2. Owner should refer to owner's procedures for
removal, handling, cleaning and disposal of
nonreusable parts, i.e. gaskets, etc.
3. Refer to Figure 2 for basic regulator and Fig-
ure 1 for the diaphragm subassembly.
B. Diaphragm Replacement:
1. Securely install the body (1) in a vise with the
knob (4) directed upwards.
2. Relax range spring (15) by turning knob (4)
CCW until rotation comes to a complete stop.
NOTE: It is not necessary to remove knob (4)
before removing the spring chamber (6) from
the body (1).
3. Remove spring chamber (6) by grasping the
flats and turning CCW. Upon removal, the
range spring (15), range spring clip (16), and
spring button (5) should remain inside the
spring chamber (6).
4. Remove diaphragm subassembly (7) consist-
ing of the actuator nut (7.3), diaphragm (7.1),
actuator post (7.2), actuator gasket (7.4),
actuator o-ring (7.5). Remove diaphragm
gasket (10).
5. Remove actuator nut (7.3) and separate all
parts of the diaphragm subassembly (7).
6. Clean body (1) diaphragm flange and all reus-
able parts according to owner's procedures.
Do not scratch diaphragm gasket seating
surface. NOTE: On regulators originally
supplied as “oxygen clean”, Option-M, main-
tenance must include a level of cleanli-
ness equal to Cashco's cleaning standard
#S-1134. On regulators originally suppled for
Sanitary Service, maintenance must include
a level of cleanliness equal to Cashco clean-
ing standard #S-1576. Contact factory for
details.
7. Inspect and replace any necessary parts.
NOTE: Use only parts manufactured and
supplied by Cashco, Inc. for these products.
See Section VIII.
8. Reassemble diaphragm subassembly (7) by
placing the actuator gasket (7.4), diaphragm
(7.1), and actuator o-ring (7.5) over the
threads of the actuator post (7.2). Place a
thread sealant compound on the threads of
the actuator post (7.2) prior to installing the
actuator nut (7.3). Install actuator nut (7.3)
and tighten to the following torque value: 15
Ft-lbs (20 Nm).
9. Place the diaphragm gasket (10) onto the
body (1) diaphragm flange. Place diaphragm
subassembly on top of the gasket (10).
10. Lubricate the threads of the body (1) with
a light
weight grease that is compatible with
service use. Rotate the spring chamber (6)
CW by hand onto the threaded portion of
the body (1) until firmly seated against the
Figure 1: Diaphragm Subassembly
WARNING
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.

IOM-P1
4
diaphragm gasket (10). Tighten to the follow-
ing torque value: 65–70 Ft lbs (88–95 Nm).
11. Pressurize with air and spray liquid leak de-
tector around body (1) and spring chamber
(2.1) to test for leakage. Ensure that an outlet
pressure is maintained during this leak test
of at least mid-range spring level; i.e. 2-100
psig (.14-6.9 Barg) range spring, 51 psig
(3.5 Barg) test pressure minimum.
C. Trim Replacement:
1. Remove spring chamber subassembly and
diaphragm subassembly per Section VI,
Steps B.1. – B.4.
2. Remove seat retainer (13) by turning CCW.
3. Remove poppet (8) and poppet spring (9).
4. Clean debris from within the body (1) cav-
ity. Clean all parts to be reused according
to owner's procedures. NOTE: On regula-
tors originally supplied as “oxygen clean”,
Option-M, maintenance must include a level
of cleanliness equal to Cashco's cleaning
standard #S-1134. On regulators originally
supplied for Sanitary Service, maintenance
must include a level of cleanliness equal to
Cashco cleaning standard #S-1576. Contact
factory for details.
5. Inspect all parts for damage and replace if
necessary. NOTE: Use only parts manufac-
tured and supplied by Cashco, Inc. for these
products. See Section VIII.
6. Place poppet spring (9) into body (1) cavity.
7. Place poppet (8) inside the poppet spring (9).
The angled seating surface of the poppet (8)
must face up toward the seat (12).
8. Install new seat retainer (13) with seat (12)
into body (1) cavity with the seat facing down-
ward toward the angled seating surface of
the poppet (8). Tighten seat retainer to the
following torque value: 6.25 Ft-lbs (8.47 Nm).
If option-S (Self-Relieving), thread the self-
relieving button (24) onto the poppet threads
(8) until top of the self-relieving button (24) is
0.050" below the top of the body (1). Confirm
this dimension using a depth micrometer.
9. Reinstall diaphragm subassembly and spring
chamber subassembly per Section VI, Steps
B.9. – B.10.
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.
11. Pressurize with air and spray liquid leak de-
tector around body (1) and spring chamber
(6) to test for leakage. Ensure that an outlet
pressure is maintained during this leak test
of at least mid-range spring level; i.e. 2-100
psig (.14-6.9 Barg) range spring, 51 psig
(3.5 Barg) test pressure minimum.

IOM-P1 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.
A5. Before replacing regulator, contact factory.
B. Worn poppet; inadequate guiding. B. Replace trim ( possible body replacement).
C. Weakened/broken poppet spring. C. Replace poppet 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, replace with larger unit.
B. Incorrect range spring (adjusting aluminum knob CW does not
raise pressure to proper level).
B. Replace range spring with proper higher range.
C. Too much droop. C1. Review droop expected
C2. Contact factory.
3. Sluggish operation.
Possible Causes Remedies
A. Fluid too viscous. A. Heat fluid. Contact factory.
4. 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. Ensure no moisture in spring chamber at temperatures below
freeze point.

IOM-P1
6
SECTION VIII
NEW REPLACEMENT UNIT:
Contact your local Cashco, Inc., Sales Represen-
tative 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 Represen-
tative 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-P1 7

IOM-P1
8
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 and given in Schedule 1 of The Equipment and Protective Systems
Indented for Use in Potentially Explosive Atmospheres Regulations 2016. 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 DIRECTIVE 2014/34/EU and THE EQUIPMENT AND PROTECTIVE SYSTEMS INTENDED FOR USE IN
POTENTIALLY EXPLOSIVE ATMOSPHERES REGULATIONS 2016
IOM ADDENDUM:

IOM-P1 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. P1-IOM
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
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