BHMY FlowMax IOM 19584F 0923 English

FlowMax Regulator ™
Instruction Manual (Rev.F)
Baker Hughes Data Classification : Public

THESE INSTRUCTIONS PROVIDE THE CUSTOMER/OPERATOR WITH IMPORTANT PRO-
JECT-SPECIFIC REFERENCE INFORMATION IN ADDITION TO THE CUSTOMER/OPERATOR’S
NORMAL OPERATION AND MAINTENANCE PROCEDURES. SINCE OPERATION AND MAINTE-
NANCE PHILOSOPHIES VARY, BAKER HUGHES COMPANY (AND ITS SUBSIDIARIES AND AF-
FILIATES) DOES NOT ATTEMPT TO DICTATE SPECIFIC PROCEDURES, BUT TO PROVIDE BA-
SIC LIMITATIONS AND REQUIREMENTS CREATED BY THE TYPE OF EQUIPMENT PROVIDED.
THESE INSTRUCTIONS ASSUME THAT OPERATORS ALREADY HAVE A GENERAL UNDER-

STANDING OF THE REQUIREMENTS FOR SAFE OPERATION OF MECHANICAL AND ELEC-
TRICAL EQUIPMENT IN POTENTIALLY HAZARDOUS ENVIRONMENTS. THEREFORE, THESE
INSTRUCTIONS SHOULD BE INTERPRETED AND APPLIED IN CONJUNCTION WITH THE
SAFETY RULES AND REGULATIONS APPLICABLE AT THE SITE AND THE PARTICULAR RE-
QUIREMENTS FOR OPERATION OF OTHER EQUIPMENT AT THE SITE.
THESE INSTRUCTIONS DO NOT PURPORT TO COVER ALL DETAILS OR VARIATIONS IN

EQUIPMENT NOR TO PROVIDE FOR EVERY POSSIBLE CONTINGENCY TO BE MET IN CON-
NECTION WITH INSTALLATION, OPERATION OR MAINTENANCE. SHOULD FURTHER INFOR-
MATION BE DESIRED OR SHOULD PARTICULAR PROBLEMS ARISE WHICH ARE NOT COV-
ERED SUFFICIENTLY FOR THE CUSTOMER/OPERATOR’S PURPOSES THE MATTER SHOULD
BE REFERRED TO BAKER HUGHES.
THE RIGHTS, OBLIGATIONS AND LIABILITIES OF BAKER HUGHES AND THE CUSTOMER/
OPERATOR ARE STRICTLY LIMITED TO THOSE EXPRESSLY PROVIDED IN THE CONTRACT
RELATING TO THE SUPPLY OF THE EQUIPMENT. NO ADDITIONAL REPRESENTATIONS OR
WARRANTIES BY BAKER HUGHES REGARDING THE EQUIPMENT OR ITS USE ARE GIVEN
OR IMPLIED BY THE ISSUE OF THESE INSTRUCTIONS.
THESE INSTRUCTIONS ARE FURNISHED TO THE CUSTOMER/OPERATOR SOLELY TO AS-

SIST IN THE INSTALLATION, TESTING, OPERATION, AND/OR MAINTENANCE OF THE EQUIP-
MENT DESCRIBED. THIS DOCUMENT SHALL NOT BE REPRODUCED IN WHOLE OR IN PART
WITHOUT THE WRITTEN APPROVAL OF BAKER HUGHES.
ii | Baker Hughes Copyright 2023 Baker Hughes Company. All rights reserved.
Table Of Contents
Product Description...................................................................................................................1
Principles of Operation..............................................................................................................2
Nameplate Information...............................................................................................................3
Regulator Markings....................................................................................................................3
Hydrostatic Testing....................................................................................................................4
Installation...................................................................................................................................4
Piping Schematics.....................................................................................................................5
Start-up and Operation..............................................................................................................12
Maintenance ...............................................................................................................................15
Bolt Torque Specifications........................................................................................................26
Troubleshooting.........................................................................................................................27
Scope Materials of Construction

This manual provides instructions for the Installation, Operation, Body & Spring Case ASTM A 395 Ductile Iron
and Maintenance of the Mooney™ FlowMax Regulator (instructions Actuator Housing A 356-T 6 Cast Aluminum
for the Series 20 and 20L Pilots can be found in separate manuals). Spring Case A 356-T 6 Cast Aluminum
This manual is divided into the following sections:
Plug Nitrile
Product Description Diaphragm

O-Ring & Seals
Nitrile/Nylon
Nitrile
The Mooney FlowMax is an easy to maintain regulator designed
Bolting ASTM B8 or Equal
to be used with a self-contained pilot system. The Mooney
FlowMax Regulator has several unique features that add to its Spring Music Wire
versatility, such as: Table 1 - Materials of Construction
• In-line maintenance
• A single maximum pressure rating for all components
• One actuator for all pressures and differentials
• A compact, low-volume actuator housing for quick response
and lightweight design
• Top-entry design
• Maximum flow at a low differential
• Increased closing force with an increase in inlet pressure
Copyright 2023 Baker Hughes Company. All rights reserved. Mooney FlowMax Regulators Instruction Manual | 1
Specifications US units Metric units Principle of Operation
Sizes 2,3,4, and 6 inch DN 50, DN 80, DN
100, DN 150
(Refer to Figure 1)
When the downstream pressure is greater than the set point of
Body Style Single Port Single Port
the pilot, the pilot is closed, resulting in equal pressure above
End Connections 150 CL FF, 150 CL Contact Factory and below the main diaphragm. With a balancing diaphragm
RF,Flanged NPT area slightly larger than the seat area, the resulting closing force,
(2” Only) along with the force of the main spring, forces the plug against
Temperature -20°F to 150°F -29°C to 66°C the seat.
Working -40°F to 175°F -40°C to 80°C With an increase in demand, the outlet pressure will begin to
Emergency drop and decrease the pressure above the main diaphragm. The
Maximum 250 psi 17 bar drop of the outlet pressure below the pilot set point will cause the
Operating pilot to open.
Differential As the pilot opens, pressure increases underneath the main
Maximum Casing 250 psi 17 bar diaphragm faster than pressure can bleed through the internal
Pressure restrictor. The imbalance in pressure on the main diaphragm
overcomes the spring force and the additional closing force from
Minimum 3 psi 0.21 bar
the balancing diaphragm, causing the plug to rise off the seat
Differential(Fully and satisfy the flow demand.
Open)
Once the flow demand is satisfied and the downstream pressure
Outlet Series 20L: 5 in 0.01 - 0.55 bar
begins to increase, the pressure above the main diaphragm and
PressureRange w.c. to 8 psi 0..21 - 17 bar in the pilot sense cavity rises. This causes the pilot to close. The
Series 20: 3 - 248 pressure below the main diaphragm bleeds through the internal
psi restrictor until pressure equalizes above and below the main
Maximum Inlet 250 psi 17 bar diaphragm. The forces of the main spring and the oversized
Pressure balancing diaphragm then close the plug on the seat.
Pilot Supply One 1/4” - 18 NPT One 1/4” - 18 NPT
Body Tap
Sense Line Tap Two 1/2” - 14 NPT Two 1/2” - 14 NPT
Table 2 - Specifications
Balancing Diaphragm
Pilot Sense Regulator Sense Line
Pilot Supply Pilot Loading Internal Restrictor
Inlet Pressure Loading Pressure Outlet Pressure
Figure 1
2 | Baker Hughes Copyright 2023 Baker Hughes Company. All rights reserved.
Nameplate Information Item Definition
FlowMax Trademarked name
S/N Serial number assigned to regulator
FM # FlowMax product identification
Size/End Conn Line size of body and type of end
connection
Max Inlet/Outlet Maximum inlet or outlet pressure
Pressure psig (bar)
Cap % Percent capacity of maximum for the
regulator
Mfg. Date Date of manufacture
Figure 2 - Nameplate Min. Differential Minimum differential required to fully
open regulator
Regulator Markings Max
Temperature
Maximum operating temperature in
degrees Fahrenheit
Loading Port
Inlet
Inlet Port
Sense Ports
Front View Top View
Figure 3 - Regulator Markings
1. American National Standards Institute (ANSI) pressure class rating of the regulator.
2. Line size of body.
3. ANSI pressure class rating of the flange.
4. Indication that the regulator has been hydrostatically tested according to code requirements.
5. The Serial Number is stamped on the spring case, spacer, and Body.
6. The Nameplate location.
Hydrostatic Testing Installation
Installation and testing of the FlowMax Regultor Personal injury, equipment damage, or leakage due to
should be made by trained, qualified personnel explosion of accumulated gas or bursting of pressure
familiar with high-pressure piping and pilot-operated containing parts, may result if this regulator is over-
regulators. pressured, or is installed where service conditions
could exceed the limits given in the specification of
this manual, or on the nameplate, or where conditions
All FlowMax regulators are hydrostatically tested at the factory
exceed any ratings of the adjacent piping or piping
prior to shipment according to ISA-S75.19-1989 and MSS-SP-61
connections. Verify the limitations of both regulator
standards. If it is necessary to retest the Regulator body, follow
and pilot to ensure neither device is overpressured.
the procedures listed below.
To reduce the chances of such injury or damage,
Note: This Procedure applies to the regulator body only. If provide pressure relieving or pressure limiting de-
actuator retesting is required, contact the factory for proper vices (as required by the U.S. code of Federal Regula-
procedures. tions, by the National Fire Codes of the National Fire
1. Disconnect and remove the pilot inlet and actuator sense Protection Association, or by other applicable codes),
control line(s). to prevent service conditions from exceeding those
limits. Additionally, physical damage to the regulator,
2. Remove the body-to-actuator bolts and remove the actuator pilot, or tubing can cause personal injury and/or prop-
and pilot. erty damage due to explosion of accumulated gas. To
reduce the chances of such injury and damage, install
the regulator in a safe location.
Note: The following installation instructions are based upon

using pilots and filters manufactured by Baker Hughes. When
using equipment from other manufacturers, please contact
Baker Hughes or the local Baker Hughes representative for
product compatibility.
1. ersonnel: Installation of the FlowMax regulator should be
P
performed by trained, qualified personnel familiar with high-
pressure piping and pilot-operated regulators.
2. rior Inspection: Inspect the main regulator, pilot, and
P
tubing for any damage that might have occurred in shipping.
Figure 4 - Installed hydrostatic plug Make sure the body, pilot sense lines, and piping are clear
3. Plug the pilot supply line in the regulator body or, if applicable, and free of foreign material.
the pilot filter. 3. Screwed End Regulators: Apply a pipe compound to the
4. Remove the cage, seat, and o-ring from the body. male threads starting one or two threads back from the end
prior to assembling the joint.
Do not damage the seat sealing surface (knife-edge).

Gas regulators installed in confined or enclosed
spaces should be provided with adequate ventilation
5. Plug the flange/actuator mounting surface on the body. to prevent the possibility of gas buildup or accumu-
Note: A plug for hydrostatically testing the Body is lation from leaks and venting. Leaks or vented gas
available from the factory (see Figure 4). may accumulate causing personal injury, death, or
property damage. Pilot spring cases and the regulator
6. Pressurize the system to the required maximum hydrostatic enclosure should be vented to a safe area away from
pressure. DO NOT EXCEED 375 PSIG (26 bar). air intakes, or any hazardous location. The vent lines
7. After the hydrostatic test is completed and the body is dry and and stacks must be protected against condensation
clean, follow the assembly procedures in the maintenance and clogging.
section of this manual.
4. langed End Regulators: Use suitable line gaskets and good
F
bolting practices with flanged bodies. Incremental tightening Piping Schematics
of the line bolts in a crisscross pattern is recommended. The following piping schematics are provided:

Note: Prior to commissioning, re-tighten actuator 1. Single Regulator with Single Pilot. Page 6
housing cap screws as they may become loose during
2. Standby Monitor set with differential pressure greater than
transit. See Page 26 for torque values.
10 psid (0.69 bar)(Monitor located downstream). Page 7
5. Orientation: The FlowMax regulator may be installed
3. Standby Monitor set with differential pressure less than 10
in any position – the best position being the one that
psid (0.69 bar)(Monitor located downstream). Page 8
provides easiest access for pilot adjustment and general
maintenance. 4. Standby Monitor set with differential pressure greater than
10 psid (0.69 bar)(Monitor located upstream). Page 9
6. Control Lines: Control sense lines should be run from the
actuator on the FlowMax regulator to a point 8 to 10 pipe 5. Standby Monitor set with differential pressure less than 10
diameters downstream from the regulator (refer to piping psid (0.69 bar)(Monitor located upstream). Page 10
schematics). Use Table 3 as a guide for the ideal tubing size 6. Working Monitor set. Page 11
to use. Reduce as necessary to connect the actuator.
All drawings show installations with the Series 20 Flowgrid pilot.
Outlet Pressure Consult factory for installation schematics of other manufacturer’s
pilot on the FlowMax regulator.
Pilot Less than 2 to 5 psi Greater than
Regulator 2 psi (0.14 (0.14 - 0.35 5 psi (0.35
with: bar) bar) bar)
Static Sense
1/2” Pipe
Line 1/2” Tubing 3/8” Tubing
minimum
(No Flow)1
Sense Line 3/4” to 1”
1/2” Pipe 1/2” Tubing
with Flow2 Pipe
1
The Flowgrid Series 20 Pilot has a static sense line.
2
The Sense line of the FlowMax actuator has flow.
Table 3 - Outlet Pressure

Note: The control line connection should be away from
areas of turbulence (such as valves, reducers, and
elbows) and should have a full opening into the pipe
free from burrs, drill peels, and weld slag. Shutoff valve
may be required in the control line(s),if installed, they
should be of the full opening type.
7. ilot Supply Lines: Run a 3/8-inch or 1/2-inch pilot supply
P
line from the upstream piping or from the Inlet port body
connection on the side of the FlowMax regulator to the pilot
Inlet port.
8. A Filter in the pilot supply line is recommended to remove
particulates from the pilot supply that could affect the
variable orifice in the pilot.
Note: A shutoff regulator is not required in the pilot
supply line, but if one is installed, it must be a full-
opening type.
9. Vent Regulators and Gauge Connections: Vent regulators
and gauge connections are recommended in the Inlet and
actuator sense piping of the FlowMax regulator.
10. I nterstage Piping: The recommended length of the
interstage piping between monitor regulators is 6 pipe
diameters or 36 inches (915 mm), whichever is greater. It is
also recommended that the interstage piping be swaged up
1 pipe diameter over the nominal port size of the regulator
for working monitor applications.
OR EXAMPLE: A station with two 2” FlowMax regulators
F
in a working monitor configuration should have interstage
piping at least 36 inches (915 mm) in length and swaged up
to a 3-inch pipe.
Piping Schematics (cont’d)
1. S
ingle Regulator/Single Pilot
(Pressure Reducing Regulator)
Typical Top View
1. Pilot supply tubing from filter OUTLET connection to the Series 20 pilot INLET port.
2. Type 30 filter mounted in inlet piping.
3. OUTLET port of Series 20 pilot connected to Loading connection on the actuator housing of the FlowMax regulator
4. Sense line connecting the SENSE Port on the Series 20 pilot to the sense port on the FlowMax actuator.
(Refer to Table 3 on Page 5 for sense piping recommendations)
5. Sense line connecting the FlowMax regulator to the downstream piping.
6. Series 20 pilot with pilot cartridge in PRV mode. Pilot LOADING port is plugged.
2. S
tandby Monitor with Differential Pressure Greater than 10 psid (0.69 bar)
(Monitor located downstream)
Operating
Regulator
Monitor
Regulator
Typical Top View
1. Pilot supply tubing from filter OUTLET to Series 20 pilot INLET port.
2. Type 30 Filter mounted in inlet piping.
3. OUTLET Port of Series 20 pilot connected to the loading connection on the actuator housing of the FlowMax regulator.
4. Sense line connecting the SENSE port on the Series 20 pilot to the sense port on the FlowMax actuator.
7. Pilot supply tubing from filter OUTLET to Series 20 pilot INLET port.
9. OUTLET port of Series 20 pilot connected to the Loading connection on the actuator housing of the FlowMax regulator.
(Same as #3, See Typical Top View)
11. Sense line connecting the FlowMax actuator to the downstream piping.
3. S
tandby Monitor with Differential Pressure Less than 10 psid (0.69 bar)
(Monitor located downstream)
VentValve
SenseValve
Operating
Regulator
Monitor Regulator
Typical Top View
1. Pilot supply tubing from filter OUTLET connection to Series 20 pilot INLET port.
3. OUTLET port of Series 20 pilot connected to the loading connection on the actuator housing of the FlowMax regulator.
7. Pilot supply tubing from filter OUTLET connection on the upstream piping connected to Series 20 pilot INLET port.
8. Type 30 filter mounted in the upstream inlet piping.
9. OUTLET port of Series 20 pilot connected to loading connection on the actuator housing of the FlowMax regulator.
(Same as #3, See typical top view)
10. Sense line connecting SENSE port on Series 20 pilot to sense port on the FlowMax actuator.
4. S
tandby Monitor with Differential Pressure Greater than 10 psid (0.69 bar)
(Monitor located upstream)
Monitor
Regulator
Operating
Regulator
Typical Top View
3. OUTLET port of Series 20 pilot connected to the Loading connection on the actuator housing of the FlowMax regulator.
4. Sense line connecting the SENSE port on the Series 20 pilot to downstream of the operating regulator.
5. Sense line connecting the FlowMax regulator to the interstage piping.
7. Pilot supply tubing from filter OUTLET connection to Series 20 Pilot INLET port.
9. OUTLET port of Series 20 pilot connected to Loading connection on the actuator housing of the FlowMax regulator.
5. S
tandby Monitor with Differential Pressure Less than 10 psid (0.69 bar)
(Monitor located upstream)
Monitor
Regulator
Operating
Regulator
Typical Top View
3. OUTLET port of Series 20 pilot connected to the loading connection on the actuator housing of the FlowMax regulator.
4. Sense line connecting the Pilot SENSE port to downstream of the operating regulator.
5. Sense line connecting the FlowMax regulator to the interstage piping.
7. Pilot supply tubing from filter OUTLET connection on the upstream piping to pilot INLET port connection.
9. OUTLET port of Series 20 pilot connected to loading connection on the actuator housing of the FlowMax regulator.
6. Working Monitor Set
1. Pilot supply tubing from filter OUTLET connection to Series 20 pilot (#1) LOADING port.
2. Pilot #1 OUTLET port connected to pilot #2 INLET port.
3. Pilot #2 OUTLET port connected to the loading connection on the actuator housing of the FlowMax regulator.
4. Sense line connecting the 1st stage FlowMax regulator to the interstage piping.
5. Sense line connecting SENSE port on Series 20 pilot (#2) to the sense port on the FlowMax actuator.
6. INLET port on the monitor Series 20 pilot (#1) is plugged.*
7. LOADING port on the Series 20 pilot (#2) is plugged.*
8. Sense line connecting the SENSE port on the monitor pilot (#1) to the downstream piping.
9. Type 30 filter mounted in the inlet piping.
10. Pilot supply tubing from filter OUTLET connection to Series 20 pilot (#3) INLET port.
11. LOADING port on the Series 20 pilot (#3) is plugged.
12. Sense line connecting SENSE port on Series 20 pilot (#3) to the sense port on the FlowMax actuator.
13. OUTLET port of Series 20 pilot (#3) connected to the loading connection on the actuator housing of the FlowMax regulator.
14. Sense line connecting the 2nd stage FlowMax regulator to the downstream piping.
Note: The INLET and LOADING ports form a common port on the Series 20 pilot
Start-up and Operation Standby Monitor
The following procedures are suggested for start up of the
FlowMax regulator equipped with Series 20 pilots. Start up of
(Upstream Operating Regulator
the FlowMax regulator should be made by trained, qualified Configuration)
personnel familiar with high pressure systems and pilot-operated
regulators. This procedure is based on the first regulator being the Operating
regulator and the second regulator being the Monitor regulator.
Note: In this configuration, installation of a shut-off valve
and a vent valve are required in the sense line of the
operating regulator to facilitate testing of the monitor
The instruction manual for the PILOT(S) being used regulator performance. See Pages. 8 and 9.
should be consulted to insure that the installation and
start up instructions for the pilot are followed. Some 1. If necessary, purge any pressure in the station.
pilots can be damaged if not installed and put into 2. Set operating regulator pilot (#1) spring at the MAXIMUM
operation correctly. setting. The sense line shut-off valve should be closed and
the sense line vent valve should be open.
Single Pressure Reducing Regulator 3. Set monitor pilot (#2) spring to the MINIMUM (zero) setting.
1. Back off the pilot adjusting screw to fully remove the spring 4. Slowly open the inlet block valve. Full inlet pressure should
compression. be present at the monitor regulator and the Monitor regulator
should be closed.
2. Slowly open the upstream block valve to pressurize the
FlowMax regulator and pilot system. The FlowMax regulator 5. Open any hand valve(s) in the pilot supply lines on both
should lock up (shut off) with zero pressure downstream. regulators. The sense line shut-off valve should remain
closed and the sense line vent valve should remain open
3. Fully open any hand valve(s) in the control line(s) and the (Refer to page 8).
pilot supply line.
6. Open a vent or downstream block valve.
4. Slightly open a downstream block valve or open a vent in
piping downstream of the FlowMax regulator. 7. Increase the pilot spring setting of the monitor regulator until
the desired monitor override setting is reached. Lock in the
5.
Slowly increase the pilot spring setting until the desired pilot setting.
downstream pressure is achieved.
8. With some flow going through the station, close the vent
6. Slowly close the downstream block valve or vent to check valve on the operating regulator sense line and open the
the FlowMax regulator for lockup (shutoff). shut-off valve on the same line. Start to lower the Pilot setting
7. Slowly open the downstream block valve to allow full flow. of the operating regulator until the desired outlet pressure is
achieved.
ote: When the set point of the operating regulator
N
becomes less than the set point of the monitor regulator,
the interstage pressure will drop from approximately
full inlet pressure to 2-4 psi (0.14-0.28 bar) above the
outlet pressure at low flow rates.
Checking Standby Monitor Operation

1. With flow going through the station, slowly open the vent
valve installed in the operating regulator sense line while
closing the shutoff valve in the same line. The outlet
pressure should begin to rise as the operating regulator
goes wide open. When the pressure reaches the setpoint
of the monitor regulator, the monitor should take control and
the interstage pressure should increase to approximately full
inlet pressure.
2. Return the system to normal operation by reversing the
process with the vent regulator being closed while the shut-
off regulator is returned to the open position. The interstage
pressure should drop to 2-4 psi (0.14-0.28 bar) above the
outlet pressure as the operating regulator regains control (at
low flows).
Standby Monitor Working Monitor
1. Purge any pressure in the station.
(Upstream Monitor Regulator
2. Set pilots #1 and #2 to a setting above the desired set points.
Configuration) 3. Set the pilot (#3) at a zero setting.
This procedure is based on the first stage regulator being the
4. Slowly open the inlet block valve to station. The s e c o n d
Monitor regulator and the second stage regulator being the
stage regulator should remain closed as a result of the pilot
Operating regulator.
#3 being set to zero.
1. If necessary, purge any pressure in the station.
5. Fully open any hand valve(s) in the control line(s) and the
2. Set first stage monitor regulator pilot spring at the MAXIMUM pilot supply line.
setting.
6. Open an outlet block valve or vent to allow flow through the
3.
Set second stage operating regulator pilot spring to the station.
MINIMUM (zero) setting.
7. Increase the setting of the second stage regulator, pilot (#3)
4. Slowly open the inlet block valve. Full inlet pressure should to the desired monitor over-ride pressure set point of the
be present at the second stage operating regulator and it station.
should be closed.
8.
Lower the setpoint of the first stage regulator pilot (#2)
5. Fully open any hand valve(s) in the control line(s) and the to the desired interstage pressure setting. The first stage
pilot supply line. regulator should begin to control the interstage pressure at
6. Open a vent or downstream block valve. the setpoint of Pilot #2.
7. Increase the set point of the second stage operating 9. Lower the setpoint of pilot #1 to take control of the system
regulator to the desired monitor over-ride set pressure. (a pressure that will be slightly lower than the final monitor
over-ride pressure).
8. Decrease the pilot spring setting of the first stage monitor
regulator until it take control at a set point just below the final 10. Raise the setpoint of pilot #3 to a maximum setting.
desired monitor over-ride set pressure. 11. Raise the setpoint of pilot #1 to maintain the exact monitor
9.
Increase the second stage operating regulator to the over-ride pressure set point.
maximum pilot setting. 12. Lower pilot #3 to the desired station outlet pressure.
10. Increase the first stage monitor regulator set pressure to the
final desired monitor over-ride set point.
11. Decrease the pilot spring setting of second stage operating
regulator until the final set point is achieved.

Note: When the set point of the operating regulator
becomes less than the set point of the monitor regulator,
the interstage pressure will rise to 2-4 psi (0.14-0.28 bar)
below the full inlet pressure (at low flows).
Checking Standby Monitor Operation

1.
With flow going through the station, slowly increase the
setting of the operating regulator. When the pressure
reaches the setpoint of the monitor regulator, the monitor
should take control and the interstage pressure should
decrease to approximately 2-4 psi (0.14-0.28 bar) above the
outlet pressure.
2. Reduce the setting of the operating regulator back to the
required outlet pressure. The interstage pressure should
increase to 2-4 psi (0.14-0.28 bar) below the inlet pressure
as the operating regulator regains control (at low flows).
Maintenance 2. Loosen and remove the cap screws securing the actuator
housing and remove the actuator from the body by lifting
straight up. DO NOT PRY.
Installation and testing of the FlowMax regulator

should be made by trained, qualified personnel famil-
iar with high-pressure piping and regulators.
Regulator parts are subject to normal wear and must be inspected

and replaced as necessary. The frequency of inspection and
replacement of parts depends on severity of service conditions
or the requirements of local, state, and federal regulations. Be
certain that the nameplates are updated to accurately indicate
any field changes in equipment, materials, service conditions, or
pressure settings.
Figure 6 - Remove actuator from regulator body
Note: The regulator and actuator have been designed to
facilitate the maintenance of the major wear components 3. Remove the cage, seat, seat o-ring and body gasket.
without the need to completely disassemble the actuator. Note: The 6” FlowMax does not have a body gasket.
Inspect the seat for damage. If any nicks, scratches, or
other damage is present on the sealing surface (knife
edge), the Seat must be replaced.
Before disassembly make sure the regulator has been Cage
isolated from the process by closing block valves
on the inlet and outlet sides of the regulator. Safely
release pressure and process fluid from the system.
Failure to complete these steps can result in personal
injury and property damage.
Seat
Partial Disassembly for Stem/Plug/
Seat Inspection
1. Disconnect actuator control/sense and pilot supply lines to
the actuator.
O-Ring
Figure 7a - Remove cage, seat, and o-ring
Figure 5 - FlowMax with tubing removed
6” FlowMax Only Plug Seal
3. There is no body gasket in the 6” design. The cage needs
to be unscrewed for removal. The housing o-ring should be
removed and inspected.
Housing
O-Ring
Figure 9 - Inspecting the plug seal

6. Remove the stem bushing from the bottom of the lower
actuator housing. Use caution to not damage the sealing
surface of the stem.
Figure 7b - 6” FlowMax: remove cage & inspect housing

o-ring
4. Remove the lower stem nut and remove the plug assembly.
Note: When removing or tightening the stem nut, use
a wrench on the stem flats to prevent the stem from
rotating and damaging the main actuator diaphragm.
Figure 10 - Removing the stem bushing

Plug
Assembly 7. Inspect the stem o-ring in the internal groove of the bushing
for wear and/or damage. Reinstall stem bushing snug tight.
Do not over torque.
Stem
Flats Stem
O-Ring
Stem-
Bushing
Figure 11 - Inspecting the stem o-ring

Figure 8 - Removing plug assembly from actuator stem
5. Inspect the plug seal and plug o-ring for damage or wear. If
damaged, the plug seal may be turned over or replaced.
Partial Assembly for 6. Ensure that the seat bore in the body is clean and install the
seat o-ring and seat into the bore in the body. Make sure that
Stem/Plug/Seat Inspection the chamfered edge of the seat is resting against the seat
o-ring and that the knife-edge sealing surface is facing up.
Note: Lightly lube o-rings before installation.
1. If the o-rings have been removed, reinstall the bushing
o-ring and the stem o-ring.
2. Screw the stem bushing into the bottom side of the lower
actuator housing until the bushing flange has bottomed on Plug
the housing. Do not over tighten.
3. Install a new o-ring in the internal plug groove. be removed
and inspected.
Seat
O-Ring
Plug
Grove Figure 14 - Proper seat orientation
7. Install the cage onto the seat. The cage should fit snugly
over the raised lip on the seat. Do not damage the seat
Figure 12 - Inspecting the plug o-ring sealing surface when installing the cage.
4. Install the plug onto the tapered end of the stem with the 8. Install the body gasket (2”, 3” & 4” models). The 6” FlowMax
plug seal facing away from the actuator. does not utilizes a body gasket.
5. Screw the stem nut on the bottom of the stem with the rubber
seal toward the plug to lock the plug assembly in place. Use Body
a wrench to hold the stem while tightening the stem nut. Gasket
Figure 15 - Installing the body gasket

9. Line up the mounting holes in the body with those in the
Figure 13 - Hold the stem while tightening the stem nut lower actuator housing, and make sure that the loading port
in the lower actuator housing is facing towards the front of
the regulator. Apply a light coating of lubricant to the housing
o-ring and lower the actuator assembly onto the body.
Use caution not to pinch the housing o-ring during
installation.
Partial Disassembly for Balancing
Diaphragm Inspection
1.
Disconnect control/sense and pilot supply lines to the
actuator.
2. Loosen the spring case cap and remove the main spring.
Housing
O-Ring
Figure 18 - Removing the main spring

Figure 16 - Installing the main actuator 3. Remove the spring case bolts, the spring case, and the
spring case o-ring.
10. Incrementally tighten the body cap screws to specified
torque values. Table 4 Page 26.
2”, 3” & 4” FlowMax Only

Note :The gap between the actuator and body should be
approx. 1/16 in (1.59 mm).
6” FlowMax Only
Note: The 6” FlowMax does not utilize a body gasket. There
should be no gap between the actuator and body.
Upper Nut Stem
Figure 19 - Removing the spring case

4.
Remove the cap screws securing the actuator housing
and remove the actuator from the regulator body by lifting
straight up. DO NOT PRY.
5. Remove the upper stem nut located on top of the Piston.
ote: When removing the upper stem nut, hold the stem
N
with a wrench at the stem flats near the plug assembly.
Figure 17 - Tightening the body cap screws Failure to do so may cause damage to the main actuator
11.
Reconnect control/sense and pilot supply lines to the diaphragm. Remove and inspect the piston, washer,
actuator. and balancing diaphragm. Inspect the piston ring and
balancing diaphragm for signs of wear and damage.
Replace as necessary.
Partial Assembly for Balancing 4. Install the washer in the piston counter bore and install
the upper stem nut. Use a wrench to hold the stem while
Diaphragm Inspection tightening the upper stem nut.
1. Install the balancing diaphragm onto the balancing
diaphragm retainer. Ensure that the diaphragm flange is Stem Nut
Washer
facing up. Once installed, the top diaphragm flange should
be pushed down flush with the counter bore surface of the
upper actuator housing.
Balancing Piston
Diaphragm
O-Ring
Balancing
Diaphragm
Retainer
Figure 22b - 3”-6” FlowMax only: Installing piston and bal-

Figure 20 - Replacing the balancing diaphragm
ancing diaphragm
2. Install the piston ring onto the piston.
Piston Ring
Washer
Figure 21 - Installing piston ring on piston

3. Install the piston onto the stem with the piston ring and
counter bore up. The bottom end of the piston should fit Figure 23 - Installing the washer in the piston counter bore
over the balancing diaphragm and hold it in place over the
5a. 2” FlowMax only: Place the balancing diaphragm o-ring into
balancing diaphragm retainer. Note that 3” -6” FlowMax
the counter bore in the upper actuator housing and install
regulators utilize a nut to hold the balancing diaphragm
the spring case onto the housing. The o-ring can be lightly
retainer in place.
stretched for ease of assembly.
Stem Nut
Balancing
Balancing Diaphragm
Diaphragm O-Ring
Retainer Piston
Figure 24a - Installing the balancing diaphragm o-ring on

the 2” FlowMax regulator
Figure 22a - Installing piston over balancing diaphragm
5b. 3”, 4” & 6” FlowMax only: Lubricate and install the balancing 9. Lower the actuator assembly onto the regulator body. Use
diaphragm o-ring into the spring case groove. Place the caution not to pinch the housing o-ring during installation.
spring case onto the housing and install cap screws to the 10. Incrementally tighten the body cap screws to specified
proper torque (refer to Table 4, page 26). torque values. Table 4 Page 27.
3” - 6”
Balancing
Diaphragm
O-Ring
Figure 24b - Installing the balancing diaphragm o-ring on
the 3”, 4” & 6” FlowMax Figure 27 - Tightening the body cap screws
6. Insert the main spring into the piston counterbore and install
the spring case cap. Note that 6” FlowMax has an additional
washer between the spring and spring case cap. Note: The gap between the actuator and body shouldbe
approx. 1/16 in (1.59 mm).
6” FlowMax Only
Note: The 6” FlowMax does not utilize a body gasket. There
11.
Reconnect control/sense and pilot supply lines to the
actuator.
Disassembly for Main Diaphragm

Inspection
1.
Disconnect control/sense and pilot supply lines to the
actuator.
Figure 25 - Installing the main spring 2. Loosen and remove the cap screws securing the actuator
7. Lightly coat the housing o-ring with lubricant and install the housing and remove the actuator from the body by lifting
body gasket. The 6” FlowMax does not utilize a body gasket, straight up. DO NOT PRY.
the housing o-ring on a 6” FlowMax is machined into the
regulator body.
Housing
O-Ring
Figure 28 - Removing the main actuator
Figure 26 - Installing the actuator on the body

8. Line up the mounting holes for the body with those in the
lower actuator housing, and make sure that the Loading port
in the lower actuator housing is facing toward the front side
of the regulator.
3. Remove the spring case cap and remove the main spring.
4. Remove the spring case capscrews and remove the spring
case.
5. Remove the upper stem nut and remove the piston from the
stem. Remove the balancing diaphragm. Use a wrench to
hold the stem while loosening the stem nut.
6. Remove the housing cap screws and remove the upper
actuator housing.
Figure 31 - Fig. 31 Inspecting stem o-ring
Assembly of Main Diaphragm

1. Install the main diaphragm stem o-ring into the internal
groove of the lower diaphragm retainer with the stem still in
place in the lower actuator housing. The groove should be
Figure 29 - Removing the housing cap screws facing up. Install the retainer on the stem.
7. Remove the balancing diaphragm retainer. Use a wrench
to hold the stem while loosening the retainer. The 2” inch
FlowMax retainer is threaded and attached directly to the
stem. The 3” - 6” FlowMax regulators utilize a nut and
washer to hold the retainer in place.
Figure 32 - Installing lower diaphragm retainer

2. The main diaphragm is a top hat design and should be
installed with the large flange down. Install the main
Retainer
diaphragm on the stem until it is bottomed on the lower
diaphragm retainer.
Figure 30 - Removing the balancing diaphragm retainer
3.
Install the upper diaphragm retainer over the threaded
8.
Remove the upper diaphragm retainer and the main end of the stem so it is resting on the top side of the main
diaphragm. Inspect the main diaphragm for any damage. diaphragm.
9. Inspect the main diaphragm stem o-rings in the upper and
lower retainers for damage and replace if necessary.
4. Install the balancing diaphragm retainer o-ring side down,
over the stem and tighten. Use a wrench to hold the stem
while tightening the retainer. The 2” inch FlowMax retainer
is threaded and attached directly to the stem. The 3” - 6”
FlowMax regulators utilize a nut and washer to hold the
retainer in place.
5. Align the small hole on the main diaphragm flange with the
alignment pin in the lower actuator housing and bottom the
diaphragm on the housing flange.
O-Ring
Housing
Alignment Figure 35 - Install the remaining actuator cap screws
Pin 10. Install the balancing diaphragm onto the Balancing
O-Ring diaphragm Retainer. Ensure that the diaphragm flange is
Main facing up. Once installed, the diaphragm flange will need to
Diaphragm be pushed down so that it is flush with counter bore surface
of the upper actuator housing.
Balancing
Diaphragm
Figure 33. - The housing alignment pin assembly for Flow-

Max actuator assemblies
6.
Install the upper housing onto the lower housing and
diaphragm. Ensure that the alignment pin engages the Figure 36 - Replacing the balancing diaphragm
alignment hole in the upper housing. 11. Install the piston ring onto the piston.
7. To hold the assembly in place, install at least two of the
housing cap screws on opposite sides of the housing and
tighten finger tight.
8. Move the stem assembly through full stroke. The stem
should move freely.
Figure 37 - Installing piston ring on piston
Figure 34 - Checking stem for free movement

9. Install and tighten the remaining actuator bolts per the torque
recommendation (Table 4, Page 26). Prior to commissioning,
re-tighten actuator housing cap screws as they may have
loosened during transit.
12. Install the piston onto the stem with the piston ring and 14a. 2” FlowMax only: Place the balancing diaphragm o-ring into
counter bore up. The bottom end of the piston should fit the counter bore in the upper actuator Housing and install
over the balancing diaphragm and hold it in place over the the spring case onto the housing. The o-ring can be lightly
balancing diaphragm Retainer. Note that 3” -6” FlowMax stretched for ease of assembly.
regulators utilize a nut to hold the balancing diaphragm
retainer in place. 2” Balancing
Diaphragm
Balancing Stem Nut O-Ring
Diaphragm
Retainer
Piston
Figure 40a - Installing the balancing diaphragm o-ring on

the 2” FlowMax
14b. 3”, 4” & 6” FlowMax only: Lubricate and install the balancing
diaphragm o-ring into the spring case groove. Place the
spring case onto the housing and install cap screws to the
Figure 38a - Installing piston over balancing diaphragm proper torque (refer to Table 4, page 27).
Washer Stem Nut
Piston
3” - 6”Bal-
ancing
Diaphragm
O-Ring O-Ring
Figure 40b - Installing the balancing diaphragm o-ring on

the 3”, 4” & 6” FlowMax
Balancing
Diaphragm
Retainer
Figure 38b - 3”-6” FlowMax only: Installing piston and bal-

ancing diaphragm
13. Install the washer in the piston counter bore and install
the upper stem nut. Use a wrench to hold the stem while
tightening the upper stem nut.
Washer
Figure 39 - Installing the washer in the piston counter bore
6. Insert the main spring into the piston counterbore and 6” FlowMax Only
install the spring case cap. NOTE: The 6” FlowMax has an
additional washer between the spring and spring case cap. Note: The 6” FlowMax does not utilize a body gasket. There
20.
Reconnect control/sense and pilot supply lines to the
actuator.
Travel Indicator Kit Installation

(Optional)
An optional travel indicator kit is available for the FlowMax
regulator. Contained in the kit is an indicator stem, indicator stem
o-ring, indicator stem o-ring retainer, spring case cap, indicator
cover o-ring, and Indicator cover. The following outlines the
installation procedures for the kit. A pre-drilled and tapped stem
nut currently exists as part of the FlowMax regulator and is not
Figure 41 - Installing the main spring included in the kit.
16. Lightly coat the housing o-ring with lubricant and install the
body gasket. The 6” FlowMax does not utilize a body gasket,
the housing o-ring on a 6” FlowMax is machined into the
regulator body.
Housing
O-Ring
Figure 44 - Travel indicator kit

1. Remove the existing spring case cap and spring. Place a
small amount of thread locking compound on the indicator
stem threads. Finger tighten the indicator stem into the stem
nut until bottomed. Use caution to not damage the indicator
Figure 42 - Installing the actuator on the body
stem sealing surface.
17. L
ine up the mounting holes for the body with those in the
lower actuator housing, and make sure that the loading port
in the lower actuator housing is facing toward the front side
of the regulator.
18. Inspect, clean, and install the seat o-ring, seat and cage into
the body.
19. Incrementally tighten the body cap screws to specified
torque values. Table 4 Page 26.
Figure 45 - Installing the indicator stem into the stem nut

2. Lubricate and insert the indicator stem o-ring into the small
counterbore in the bottom of the new spring case cap.
Figure 43 - Tightening the body cap screws

Note: The gap between the actuator and body should be
approx. 1/16 in (1.59 mm).
5. Install the o-ring onto the indicator cover. Lightly lubricate
Stem the o-ring and threads. Screw the indicator cover into the
O-Ring spring case cap until bottomed.
Counterbore
Figure 49 - Installing the indicator cover

Figure 46 - Installing the indictor stem o-ring
3. Install the threaded indicator o-ring retainer into the spring Installation of Reduced Capacity Trim
case cap until bottomed. Check to ensure the indicator stem 1. Disconnect the actuator control/sense and the pilot supply
o-ring is installed correctly and there is a visible hole through tubing.
the cap.
2. Remove the cap screws securing the actuator housing and
remove the actuator from the body by lifting straight up. DO
NOT PRY.
Figure 47 - Installing the o-ring retainer

4. Reinstall the main spring. Install the spring case cap o-ring
and lightly lubricate the o-ring and threads. Thread the spring
case cap onto the spring case until bottomed. NOTE: The 6” Figure 50 - Remove the actuator housing assembly
FlowMax has an additional washer between the spring and
spring case cap. 3. Remove the stem nut. Use a wrench to hold the stem while
loosening the stem nut.
Figure 48 - Installing the spring case cap
5. Use a socket wrench to tighten the stem nut back onto stem.
Use a wrench to hold the stem while tightening the stem nut.
6. Reassembly the actuator onto the regulator body. Refer to
steps 8-11 on pages 17 & 18.
Cleaning
1. DO NOT clean o-ring grooves with sharp metal tools.
The bottom of the grooves must have a smooth finish to
prevent leakage. The mating surface of adjacent parts must
also be smooth to prevent leakage.
Figure 51 - Remove the stem nut

4. Replace the plug retainer with the reduced capacity plug
retainer.
Reduced Ca-
pacity Plug
Retainer
Figure 52 - Location of the reduced capacity plug retainer
FlowMax Bolting Torques Lb-Ft (n-m)

2” 3” 4” 6”
Actuator Housing Cap Screws 6-7 (8-9 ) 10-12 (14-16) 10-12 (14-16) 15-16 (20-22)
Stem Nut 7-8 (9-11) 8-10 (11-14) 10-12 (14-16) 10-12 (14-16)
Spring Case 5-6 (7-8) 6-7 (8-9) 6-7 (8-9) 8-10 (11-14)
Plug Nut 7-10 (9-14) 7-10 (9-14) 7-10 (9-14) 7-10 (9-14)
Body Cap Screws 12-16 (16-22) 12-16 (16-22) 12-16 (16-22) 16-20 (22-27)
Table 4 - FlowMax Bolting Torques
Troubleshooting
Problem Solution
The regulator will not shut-off 1. Verify the clearance between the actuator and body is even
2. Check actuator to body bolts - tighten if necessary
3. Check the pilot for excess friction (“sticking open”)
4. Check main spring
5. Check the plug seal for damage
6. Check the seat for any nicks or damage to the sealing surface
7. Check for damage to the seat o-ring
8. Check for obstructions in the stem hole
9. Check for failure of the balancing diaphragm
10. Check for blockage of the internal restrictor
Regulator will not open 1. Check if any valves in the sense line are not fully open
2. Check the pilot set point
3. Check that existing piping matches the piping schematics
4. Check for binding
5. Check the main diaphragm for damage
Erratic Behavior 1. Check the location of the sense line (away from pipes, fittings, and other turbulent
locations)
2. Check that the size of the sense line is adequate (refer to recommendations on page 5)
3. Check if any valves in the sense line are not fully open
4. Check the pilot for excess friction (“sticking”)
5. Check for excess friction in the actuator
Notes
Notes
Find the nearest local Channel Partner in your area:
valves.bakerhughes.com/contact-us
Tech Field Support & Warranty:

Phone: +1-866-827-5378
[email protected]
valves.bakerhughes.com
Copyright 2023 Baker Hughes Company. All rights reserved. Baker Hughes provides this information on
an “as is” basis for general information purposes. Baker Hughes does not make any representation as to
the accuracy or completeness of the information and makes no warranties of any kind, specific, implied or
oral, to the fullest extent permissible by law, including those of merchantability and fitness for a particular
purpose or use. Baker Hughes hereby disclaims any and all liability for any direct, indirect, consequential or
special damages, claims for lost profits, or third party claims arising from the use of the information, whether
a claim is asserted in contract, tort, or otherwise. Baker Hughes reserves the right to make changes in
specifications and features shown herein, or discontinue the product described at any time without notice or
obligation. Contact your Baker Hughes representative for the most current information. The Baker Hughes
logo, FlowMax and Mooney are trademarks of Baker Hughes Company. Other company names and product
names used in this document are the registered trademarks or trademarks of their respective owners.
BHMY-FlowMax-IOM-19584F-0923 09/2023 bakerhughes.com

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FlowMax Regulator ™

Instruction Manual (Rev.F)

Baker Hughes Data Classification : Public

THESE INSTRUCTIONS ASSUME THAT OPERATORS ALREADY HAVE A GENERAL UNDER-

THESE INSTRUCTIONS DO NOT PURPORT TO COVER ALL DETAILS OR VARIATIONS IN

THESE INSTRUCTIONS ARE FURNISHED TO THE CUSTOMER/OPERATOR SOLELY TO AS-

Scope Materials of Construction

Product Description Diaphragm

Pilot Supply Pilot Loading Internal Restrictor

Inlet Pressure Loading Pressure Outlet Pressure

Front View Top View

Figure 3 - Regulator Markings

Note: The following installation instructions are based upon

Do not damage the seat sealing surface (knife-edge).

Table 3 - Outlet Pressure

Typical Top View

Typical Top View

Typical Top View

Typical Top View

Typical Top View

Checking Standby Monitor Operation

Checking Standby Monitor Operation

Installation and testing of the FlowMax regulator

Regulator parts are subject to normal wear and must be inspected

Figure 7a - Remove cage, seat, and o-ring

Figure 5 - FlowMax with tubing removed

Figure 9 - Inspecting the plug seal

Figure 7b - 6” FlowMax: remove cage & inspect housing

Figure 10 - Removing the stem bushing

Figure 11 - Inspecting the stem o-ring

Figure 15 - Installing the body gasket

Figure 18 - Removing the main spring

2”, 3” & 4” FlowMax Only

Figure 19 - Removing the spring case

Figure 22b - 3”-6” FlowMax only: Installing piston and bal-

Figure 21 - Installing piston ring on piston

Figure 24a - Installing the balancing diaphragm o-ring on

Figure 22a - Installing piston over balancing diaphragm

Disassembly for Main Diaphragm

Figure 28 - Removing the main actuator

Figure 26 - Installing the actuator on the body

Figure 31 - Fig. 31 Inspecting stem o-ring

Assembly of Main Diaphragm

Figure 32 - Installing lower diaphragm retainer

Figure 33. - The housing alignment pin assembly for Flow-

Figure 37 - Installing piston ring on piston

Figure 34 - Checking stem for free movement

Figure 40a - Installing the balancing diaphragm o-ring on

Washer Stem Nut

Figure 40b - Installing the balancing diaphragm o-ring on

Figure 38b - 3”-6” FlowMax only: Installing piston and bal-

Figure 39 - Installing the washer in the piston counter bore

Travel Indicator Kit Installation

Figure 44 - Travel indicator kit

Figure 45 - Installing the indicator stem into the stem nut

2”, 3” & 4” FlowMax Only

Figure 49 - Installing the indicator cover

Figure 47 - Installing the o-ring retainer

Figure 48 - Installing the spring case cap