cashco P5 Instruction manual

INSTALLATION, OPERATION & MAINTENANCE MANUAL (IOM) IOM-P5
02-20
SECTION I
I. DESCRIPTION AND SCOPE
The Model P5 is a pressure reducing regulator used to control downstream (outlet or P2 ) pressure. The unit is suitable
for gaseous or liquid services. Available in sizes 1/4" (DN8), 3/8" (DN10) and 1/2" (DN15). Refer to Technical Bulletin
P5-TB for design conditions and selection recommendations.
SECTION II
II. INSTALLATION
MODEL P5
PISTON SENSING 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 relief
device if the inlet pressure could exceed the pres-
sure 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 in-
stalling the regulator. Strainers are recommended.
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.
7. In placing thread sealant on pipe ends prior to en-
gagement, ensure that excess material is removed
and not allowed to enter the regulator upon startup.
8. Flow Direction: Install so the flow direction matches
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): Regulator
may be rotated around the pipe axis 360°. Recom-
mended position is with knob (4) vertical upwards.
11. Regulators are not to be buried underground.
12. For insulated piping systems, recommendation is
to not insulate regulator.
ISO Registered Company

IOM-P52
SECTION IV
IV. STARTUP
SECTION V
V. SHUTDOWN
SECTION III
III. PRINCIPLE OF OPERATION
1. Movement occurs as pressure variations regis-
ter on the piston (14). The registering pressure
is the outlet, P2, or downstream pressure. The
range spring (15) opposes piston movement. As
outlet pressure drops, the range spring pushes
the piston down, opening the port; as outlet pres-
sure increases, the piston pushes up and the port
opening closes.
2. A failure of the piston seals (19.20) 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
piston (see Section IV. Startup, Step 7). Higher press-
ures could damage the diaphragm. (Field hydrostatic
tests frequently destroy diaphragms. DO NOT HYDRO-
STATIC 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 ob-
serve 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-P5 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 Model P5 basic regula-
tor and Figure 1 for the piston subassembly.
B. Piston 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 the knob
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. Remove pusher plate (18).
4. Remove snap ring (7) from piston.
5. Lift piston (14) out of body (1) and remove back-
up ring (19) and piston o-ring (20). Remove
body gasket (10).
6. Clean body (1) according to owner's proce-
dures. NOTE: On regulators originally supplied
as “oxygen clean”, Option-M, maintenance
must include a level of cleanliness equal to
Cashco's cleaning standard #S-1134. Contact
factory for details.
7. Inspect and replace any necessary parts.
Use only parts manufactured and supplied by
Cashco, Inc. for these products. See Section
VIII.
8. Place the gasket (10) onto the body (1) flange.
Use o-ring lube on o-ring (20) and slide o-ring
and back-up ring (19) on piston (14). Place
piston subassembly into the body (1).
9. Install snap ring (7) above piston assembly.
Position pusher plate (18) on top of piston post.
10. Lubricate the threads of the body (1) with a
lightweight grease that is compatible with ser-
vice use. Rotate the spring chamber (6) CW by
hand onto the threaded portion of the body (1)
until firmly seated against the body gasket (10).
Tighten to the following torque value: 65–70 Ft
lbs (88–95 Nm).
11. Pressurize with air and spray liquid leak detec-
tor 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.
Figure 1:
Piston 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-P54
C. Trim Replacement:
1. Remove spring chamber subassembly and
piston subassembly per Section VI, Steps B.1.
– B.5.
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 stan-
dard #S-1134. Contact factory for details.
5. Inspect all parts for damage and replace if nec-
essary. NOTE: Use only parts manufactured
and supplied by Cashco, Inc. for these products.
See Section VIII.
6. Place poppet spring (9) into body cavity.
7. Place poppet (8) inside the poppet spring (9).
The angled seating surface of the poppet must
face up toward the seat (12).
8. Install new seat retainer (13) with seat (12) into
body (1) cavity with the seat facing downward
toward the angled seating surface of the poppet
(8). Tighten seat retainer to the following torque
value: 6.25 Ft-lbs (8.47 Nm).
9. Reinstall piston subassembly and spring cham-
ber assembly per Section VI, Steps B.8. – B.11.
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 detec-
tor 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-P5 5
SECTION VII
VII. TROUBLE SHOOTING GUIDE
2. Regulator can not pass sufficient flow.
1. Erratic operation; chattering.
4. Excessive pressure downstream.
3. Sluggish operation.
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.
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.
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. Too much droop. B1. Review droop expected.
B2. Contact factory.
Possible Causes Remedies
A. Fluid too viscous. A. Heat fluid. Contact factory.
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 piston movement. D. Ensure no moisture in spring chamber at temperatures below freeze point.

IOM-P56
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-P5 7
Figure 2:
Repair Parts
Item No. Description Kit B
1 Body
2 Adjusting Screw
3 Knob Nut
4 Knob
5 Spring Button
6 Spring Chamber
7 Snap Ring-----------------------------‡‡
8 Poppet --------------------------------- ‡‡
9 Poppet Spring ----------------------- ‡‡
10 Body Gasket ------------------------- ‡‡
12 Seat ------------------------------------ ‡‡
13 Seat Retainer ------------------------ ‡‡
14 Piston
15 Range Spring
16 Spring Clip
18 Pusher Plate
19 Back-up Ring -------------------------‡‡
20 Piston O-ring--------------------------‡‡
21 Inline Filter---------------------------- ‡‡
39 Snap in cover
‡‡ Recommended Spare Part

IOM-P58
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-P5 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. P5-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
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