INSTALLATION / OPERATION / MAINTENANCE MANUAL FOR … Flowmax Manual.pdf · PAT. PENDING 730-091-01 Table 2 ... INSTALLATION / OPERATION / MAINTENANCE MANUAL FOR THE FlowMaxTM REGULATOR

PRODUCT DESCRIPTION...................... 1PRINCIPLE OF OPERATION.................. 2REGULATOR MARKINGS...................... 3NAMEPLATE INFORMATION................ 3HYDROSTATIC TESTING....................... 4INSTALLATION .....................................5-6PIPING SCHEMATICS........................... 6-12START-UP AND OPERATION.................13-15MAINTENANCE......................................16-26BOLT TORQUE SPECIFICATIONS ....... 26TROUBLESHOOTING ............................27WARRANTY........................................... 27

SPECIFICATIONS

FlowMaxTM

PAT. PENDING730-091-01

Table 2

MATERIALS OF CONSTRUCTION Table 1

This manual provides instructions for theInstallation, Operation, and Maintenance ofthe FlowMax Regulator (instructions for theSeries 20 and 20L Pilots can be found inseparate manuals). This manual is dividedinto the following sections:

PRODUCT DESCRIPTION

INSTALLATION / OPERATION / MAINTENANCE MANUALFOR THE FlowMaxTM REGULATOR

SCOPE

The FlowMax is an easy to maintainregulator designed to be used with aself-contained pilot system. TheFlowMax Regulator has severalunique features that add to itsversatility, such as:

- In-line maintenance

- A single Maximum PressureRating for all components

- One Actuator for all pressuresand differentials

- A compact, low-volume Actuatorhousing for quick response andlightweight design

- Top-entry design

- Maximum flow at a lowdifferential

- Increased closing force with anincrease in inlet pressure

The 2" FlowMaxTM Regulatorwith a Series 20 Pilot and Type 30A Filter.

SEZIS HCNI6dna,4,3,2

ELYTSYDOB TROPELGNIS

SNOITCENNOCDNE FRLC051,FFLC051)YLNO"2(TPN,DEGNALF

TCATNOCYROTCAF

ERUTAREPMET F051OTF02-GNIKROWF571OTF04-YCNEGREME

C56OTC82-GNIKROWC08OTC04-YCNEGREME

GNITAREPOMUMIXAMLAITNEREFFID GISP052 2mc/gk6.71

GNISACMUMIXAMERUSSRP GISP052 2mc/gk6.71

LAITNEREFFIDMUMINIM)nepOylluF( ISP3 2mc/gk02.0

TELNIMUMIXAMERUSSERP GISP052 2mc/gk6.71

ERUSSERPTELTUOEGNAR

isp8ot.c.w.i5:L02SEIRESisp842otisp3:02SEIRES

2mc/gk65.ot10.2mc/gk4.71ot2.

PATYDOBYLPPUSTOLIP TPN81-"4/1ENO

PATENILESNES TPN41-"2/1OWT

YDOB NORIELITCUD593AMTSA

GNISUOHROTAUTCA MUNIMULATSAC6T-653A

ESACGNIRPS MUNIMULATSAC6T-653A

GULP ELIRTIN

SMGARHPAID NOLYN/ELIRTIN

SLAES&GNIR-O ELIRTIN

GNITLOB LAUQERO8BMTSA

GNIRPS ERIWCISUM

PRINCIPLE OF OPERATIONWhen the downstream pressure is greater thanthe set point of the pilot, the pilot is closed,resulting in equal pressure above and belowthe main diaphragm. With a balancingdiaphragm area slightly larger than the seatarea, the resulting closing force, along with theforce of the main spring, forces the plugagainst the seat.

With an increase in demand, the outletpressure will begin to drop and decrease thepressure above the main diaphragm. The dropof the outlet pressure below the pilot set pointwill cause the pilot to open. As the pilot opens,pressure increases underneath the maindiaphragm faster than pressure can bleed

through the internal restrictor. The imbalancein pressure on the main diaphragm overcomesthe spring force and the additional closingforce from the balancing diaphragm, causingthe plug to rise off the seat and satisfy the flowdemand.

Once the flow demand is satisfied and thedownstream pressure begins to increase, thepressure above the main diaphragm and inthe pilot sense cavity rises. This causes thepilot to close. The pressure below the maindiaphragm bleeds through the internalrestrictor until pressure equalizes above andbelow the main diaphragm. The forces of themain spring and the oversized balancingdiaphragm then close the plug on the seat.

Figure 1

-2-

REGULATOR MARKINGS AND PORT IDENTIFICATION

TOP VIEWFRONT VIEW

1. American National Standards Institute (ANSI) pressure class rating of the regulator.2. Line size of body.3. ANSI pressure class rating of the flanges.4. Indication that the regulator has been hydrostatically tested to Code requirements.5. The Serial Number is stamped on the Actuator Housing, Regulator Body, and Nameplate6. The Nameplate location.

-3-

Figure 3

NAMEPLATE INFORMATION

ITEMFlowMaxACT MAT’L

FM #SIZE/END CONN

MAX INLETMAX OUTLETSERIAL NUMBER

CAP

MFG DATEMIN DIFF

MAX TEMP

MAX DIFF

DEFINITIONTrademarked nameMaterial the actuator ismanufactured fromFlowMax product identificationLine size of body and type ofend connectionMaximum inlet pressureMaximum outlet pressureSerial number assigned toregulatorPercent capacity of maximumfor the regulatorDate of manufactureMinimum differential required tofully open regulatorMaximum OperatingTemperature in degreesMaximum Allowable Operatingpressure differential

Figure 2

remove the Actuator and Pilot.

3. Plug the Pilot supply line in the RegulatorBody or, if applicable, the Pilot Filter.

4. Remove the Cage, Seat, and O-ring fromthe Body. CAUTION! DO NOT DAMAGE THESEAT SEALING SURFACE (KNIFE-EDGE).

5. Plug the Flange/Actuator mounting surfaceon the body.

NOTE: A plug for hydrostatically testingthe Body is available from the Factory(See Figure 4).

6. Pressurize the system to the requiredmaximum hydrostatic pressure. DO NOTEXCEED 375 PSIG.

7. After the Hydrostatic test is completed andthe body is dry and clean, follow the Assemblyprocedures in the MAINTENANCE section ofthis manual.

All FlowMax Regulators are hydrostaticallytested at the factory prior to shipmentaccording to ISA-S75.19-1989 and MSS-SP-61 standards. If it is necessary to retest theRegulator body, follow the procedures listedbelow.

NOTE: This Procedure applies to theRegulator Body only. If Actuator retestingis required, contact the Factory for properprocedures.

1. Disconnect and remove the Pilot Inlet andActuator Sense control line(s).

2. Remove the Body-to-Actuator bolts and

HYDROSTATIC TESTING

-4-

Installation and testing of the FlowMaxRegulator should be made bytrained,qualified personnel familiar withhigh-pressure piping and pilot-operatedregulators.

Fig. 4 Installed Hydrostatic Plug

NOTE:The Control line connectionshould be away from areas of turbulence(such as valves, reducers, and elbows)and should have a full opening into thepipe free from burrs, drill peels, and weldslag. Shutoff valves may be required inthe control line(s), if installed, theyshould be of the full opening type.

Personal injury, equipment damage, orleakage due to explosion of accumulated gasor bursting of pressure containing parts mayresult if this valve/regulator is overpressuredor is installed where service conditions couldexceed the limits given in the specification ofthis manual or on the nameplate, or whereconditions exceed any ratings of the adjacentpiping or piping connections. Verify thelimitations of both valve and pilot to ensureneither device is overpressured. To avoidsuch injury or damage, provide pressurerelieving or pressure limiting devices (asrequired by the U.S. code of FederalRegulations, by the National Fire Codes of theNational Fire Protection Association, or byother applicable codes) to prevent serviceconditions from exceeding those limits.Additionally, physical damage to the regulator,pilot, or tubing can cause personal injury and/or property damage due to explosion ofaccumulated gas. To avoid injury and damage,install the valve in a safe location.

INSTALLATION

-5-

NOTE: The following installationinstructions are based upon using Pilotsand Filters manufactured by MooneyControls, DMD-Roots Division, Dresser.When using equipment from othermanufacturers, please contact MooneyControls or the local Mooney ControlsRepresentative for product compatibility.

1. PERSONNEL: Installation of the FlowMaxRegulator should be performed by trained,qualified personnel familiar with high-pressurepiping and Pilot-operated Regulators.

2. PRIOR INSPECTION: Inspect the mainRegulator, Pilot, and Tubing for any damagethat might have occurred in shipping. Makesure the Body, Pilot Sense lines, and pipingare clear and free of foreign material.

3. SCREWED END REGULATORS: Apply apipe compound to the male threads startingone or two threads back from the end prior toassembling the joint.

4. FLANGED END REGULATORS: Usesuitable line gaskets and good boltingpractices with flanged bodies. Incrementaltightening of the line bolts in a crisscrosspattern is recommended.

WARNINGGas Regulators installed in confined orenclosed spaces should be provided withadequate ventilation to prevent the possibilityof gas buildup or accumulation from leaksand venting. Leaks or vented gas mayaccumulate causing personal injury, death,or property damage. Pilot spring cases andthe regulator enclosure should be vented to asafe area away from air intakes, or anyhazardous location. The vent lines and stacksmust be protected against condensation andclogging.

5. ORIENTATION: The FlowMax Regulatormay be installed in any position – the bestposition being the one that provides easiestaccess for Pilot adjustment and generalmaintenance.

6. CONTROL LINES: Control Sense linesshould be run from the Actuator on theFlowMax Regulator to a point 8 to 10 pipediameters downstream from the regulator(refer to Piping Schematics). Use Table 3 asa guide for the ideal tubing size to use.Reduce as necessary to connect the Actuator.

Table 3

*The FLOWGRIDTM Series 20 Pilot has a static sense line.** The Sense line of the FlowMax Actuator has flow.

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ENILESNES**WOLFHTIW

"1OT"4/3EPIP EPIP"2/1 GNIBUT"2/1

7. PILOT SUPPLY LINES: Run a 3/8-inch or1/2-inch Pilot supply line from the upstreampiping or from the Inlet Port body connectionon the side of the FlowMax Regulator to thePilot Inlet port

8. A FILTER in the Pilot Supply line isrecommended to remove particulates from thePilot supply that could affect the variableorifice in the Pilot.

NOTE: A shutoff valve is not required inthe Pilot supply line, but if one is installed,it must be a full-opening type.

9. VENT VALVES AND GAUGECONNECTIONS: Vent valves and gaugeconnections are recommended in the Inlet and

Actuator Sense piping of the FlowMaxRegulator.

10. INTERSTAGE PIPING : The recommendedlength of the interstage piping betweenmonitor regulators is 6 pipe diameters or 36inches, whichever is greater. It is alsorecommended that the interstage piping beswaged up 1 pipe diameter over the nominalport size of the valve for Working Monitorapplications.

FOR EXAMPLE: A station with two2” FlowMax Regulators in a Working Monitorconfiguration should have interstage piping atleast 36 inches in length and swaged up to a3-inch pipe.

PIPING SCHEMATICSThe following piping schematics are provided:

1. Single Regulator with Single Pilot. Page 7

2. Standby Monitor set with differentialpressure greater than 10 psid (Monitorlocated downstream). Page 8

3. Standby Monitor set with differentialpressure less than 10 psid (Monitor locateddownstream). Page 9

4. Standby Monitor set with differentialpressure greater than 10 psid (Monitorlocated upstream). Page 10

5. Standby Monitor set with differentialpressure less than 10 psid (Monitor locatedupstream). Page 11

6. Working Monitor set. Page 12

All drawings show installations with the Series20 FLOWGRID Pilot. Consult factory forinstallation schematics of othermanufacturer ’s pilot on the FlowMaxRegulator.

-6-

INSTALLATION (cont'd)

NOTES

PIPING SCHEMATICS (cont'd)

SINGLE REGULATOR / SINGLE PILOT(PRESSURE REDUCING VALVE)

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 Regulator4. Sense line connecting the SENSE Port on the Series 20 Pilot to the Sense Port on the

FlowMaxTM 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.

TYPICAL TOP VIEW

-7-

PIPING SCHEMATICS (cont'd)STANDBY MONITOR WITH DIFFERENTIAL PRESSUREGREATER THAN 10 PSID (Monitor located downstream)

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 FlowMaxTM Regulator.4. Sense line connecting the SENSE Port on the Series 20 Pilot to the Sense Port on the

FlowMaxTM Actuator. (Refer to Table 3 on Page 5 for Sense piping recommendations)5. Sense line connecting the FlowMaxTM Regulator to the downstream piping.6. Series 20 Pilot with pilot cartridge in PRV mode. Pilot LOADING Port is plugged.7. Pilot supply tubing from Filter OUTLET to Series 20 Pilot INLET Port.8. Type 30 Filter mounted in Inlet Piping.9. OUTLET Port of Series 20 Pilot connected to the Loading connection on the Actuator

Housing of the FlowMaxTM Regulator (Same as #3, See Typical Top View).10. Sense line connecting the SENSE Port on the Series 20 Pilot to the Sense Port on the

FlowMaxTM Actuator.11. Sense line connecting the FlowMaxTM Actuator to the downstream piping.12. Series 20 Pilot with pilot cartridge in PRV mode. Pilot LOADING Port is plugged.

TYPICAL TOP VIEW

-8-

MONITORREGULATOR

OPERATINGREGULATOR

STANDBY MONITOR WITH DIFFERENTIAL PRESSURELESS THAN 10 PSID (Monitor located downstream)

1. Pilot supply tubing from Filter OUTLET connection 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 FlowMaxTM Regulator.4. Sense line connecting the SENSE Port on the Series 20 Pilot to the Sense Port on the

FlowMaxTM Actuator. (Refer to Table 3 on Page 5 for Sense piping recommendations)5. Sense line connecting the FlowMaxTM Regulator to the downstream piping.6. Series 20 Pilot with pilot cartridge in PRV mode. Pilot LOADING Port is plugged.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 FlowMaxTM Regulator (Same as #3, See Typical Top View).10. Sense line connecting SENSE Port on Series 20 Pilot to Sense Port on the FlowMaxTM

Actuator.11. Sense line connecting the FlowMaxTM Actuator to the downstream piping.12. Series 20 Pilot with pilot cartridge in PRV mode. Pilot LOADING Port is plugged.


OPERATINGREGULATOR

MONITORREGULATOR

TYPICAL TOP VIEW

-9-

STANDBY MONITOR WITH DIFFERENTIAL PRESSUREGREATER THAN 10 PSID (Monitor located upstream)


Housing of the FlowMaxTM Regulator.4. Sense line connecting the SENSE Port on the Series 20 Pilot to downstream of the Operating

Regulator. (Refer to Table 3 on Page 5 for Sense piping recommendations)5. Sense line connecting the FlowMaxTM Regulator to the interstage piping.6. Series 20 Pilot with pilot cartridge in PRV mode. Pilot LOADING Port is plugged.7. Pilot supply tubing from Filter OUTLET connection to Series 20 Pilot INLET Port.8. Type 30 Filter mounted in Inlet Piping.9. OUTLET Port of Series 20 Pilot connected to Loading connection on the Actuator Housing




OPERATINGREGULATOR

MONITORREGULATOR

TYPICAL TOP VIEW

-10-


Housing of the FlowMaxTM Regulator.4. Sense line connecting the Pilot SENSE port to downstream of the Operating Regulator. (Refer to Table 3 on Page 5 for Sense piping recommendations)5. Sense line connecting the FlowMaxTM Regulator to the interstage piping.6. Series 20 Pilot with pilot cartridge in PRV mode. Pilot LOADING Port is plugged.7. Pilot supply tubing from Filter OUTLET connection on the Upstream piping to Pilot INLET

Port connection.8. Type 30 Filter mounted in Inlet Piping.9. OUTLET Port of Series 20 Pilot connected to Loading connection on the Actuator Housing



STANDBY MONITOR WITH DIFFERENTIAL PRESSURELESS THAN 10 PSID (Monitor located upstream)


MONITORREGULATOR

OPERATINGREGULATOR

TYPICAL TOP VIEW

-11-

1. Pilot supply tubing from Filter OUTLET connection to Series 20 Pilot (#1) INLET Port.2. Pilot #1 OUTLET Port connected to Pilot #2 LOADING Port.3. Pilot #2 OUTLET Port connected to the Loading connection on the Actuator Housing of the

FlowMaxTM Regulator.4. Sense line connecting the 1st Stage FlowMaxTM Regulator to the Interstage piping.

(Refer to Table 3 on Page 5 for Sense piping recommendations)5. Sense line connecting SENSE Port on Series 20 Pilot (#2) to the Sense Port on the

FlowMaxTM Actuator.6. LOADING Port on the Monitor Series 20 Pilot (#1) is plugged.*7. INLET 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

FlowMaxTM Actuator.13. OUTLET Port of Series 20 Pilot (#3) connected to the Loading Connection on the Actuator

Housing of the FlowMaxTM Regulator.14. Sense line connecting the 2nd Stage FlowMaxTM Regulator to the downstream piping. * The INLET and LOADING Ports form a common port on the Series 20 Pilot


WORKING MONITOR

1st STAGEREGULATOR

2nd STAGEREGULATOR

-12-

The following procedures are suggested forstart up of the FlowMaxTM Regulator equippedwith Series 20 Pilots. Start up of theFlowMaxTM Regulator should be made bytrained, qualified personnel familiar with high-pressure systems and pilot-operatedregulators.

The instruction manual for the PILOT(S)being used should be consulted to insurethat the installation and start upinstructions for the pilot are followed.Some pilots can be damaged if notinstalled and put into operation correctly.

SINGLE PRESSURE REDUCINGREGULATOR

1. Back off the pilot adjusting screw to fullyremove the spring compression.

2. Fully open any hand valve(s) in the controlline(s) and the Pilot supply line.

3. Slowly open the upstream block valve topressurize the FlowMaxTM Regulator and pilotsystem. The FlowMaxTM Regulator should lockup (shut off) with zero pressure downstream.

4. Slightly open a downstream block valve oropen a vent in piping downstream of theFlowMaxTM Regulator.

5. Slowly increase the pilot spring setting untilthe desired downstream pressure is achieved.

6. Slowly close the downstream block valveor vent to check the FlowMaxTM Regulator forlockup (shutoff).

7. Slowly open the downstream block valve toallow full flow.

START UP AND OPERATION

STANDBY MONITOR(Upstream Operating Regulator Configuration)

This procedure is based on the first regulatorbeing the Operating regulator and the secondregulator being the Monitor regulator.

NOTE: In this configuration, installation ofa shut-off valve and a vent valve arerequired in the Sense line of the Operatingregulator to facilitate testing of the Monitorregulator performance. See Pgs. 8 and 9.

1. If necessary, purge any pressure in thestation.

2. Set Operating regulator pilot (#1) spring atthe MAXIMUM setting. The Sense line shut-off valve should be closed and the Sense linevent valve should be open.

3. Set Monitor pilot (#2) spring to the MINIMUM(zero) setting.

4. Slowly open the inlet block valve. Full inletpressure should be present at the Monitorregulator and the Monitor regulator should beclosed.

5. Open a vent or downstream block valve.

6. Increase the Pilot spring setting of theMonitor Regulator until the desired monitoroverride setting is reached. Lock in the pilotsetting.

7. With some flow going through the station,close the vent valve on the Operating regulatorSense line and open the shut-off valve on thesame line. Start to lower the Pilot setting ofthe Operating regulator until the desired outletpressure is achieved.

NOTE: When the set point of the Operatingregulator becomes less than the set pointof the Monitor regulator, the interstagepressure will drop from approximately fullinlet pressure to 2-4 PSI above the outletpressure at low flow rates.

CHECKING STANDBY MONITOR OPERATION

1. With flow going through the station, slowlyopen the vent valve installed in the Operatingregulator Sense line while closing the shut-off valve in the same line. The outlet pressureshould begin to rise as the Operating regulator

-13-

NOTES

goes wide open. When the pressure reachesthe setpoint of the Monitor Regulator, theMonitor should take control and the interstagepressure should increase to approximately fullinlet pressure.

2. Return the system to normal operation byreversing the process with the vent valve beingclosed while the shut-off valve is returned tothe open position. The interstage pressureshould drop to 2-4 PSI above the outletpressure as the Operating Regulator regainscontrol.

STANDBY MONITOR(Upstream Monitor Regulator Configuration)

This procedure is based on the first regulatorbeing the Monitor regulator and the secondregulator being the Operating regulator.

1. If necessary, purge any pressure in thestation.

2. Set Operating regulator pilot (#2) spring atthe MAXIMUM setting.

3. Set Monitor pilot (#1) spring to the MINIMUM(zero) setting.

4. Slowly open the inlet block valve. Full inletpressure should be present at the Monitorregulator and the Monitor regulator should beclosed.

5. Open a vent or downstream block valve.

6. Increase the Pilot spring setting of theMonitor Regulator until the desired monitoroverride setting is reached. Lock in the pilotsetting.

7. With some flow going through the station,start to lower the Pilot setting of the OperatingRegulator until the desired outlet pressure isachieved.

NOTE: When the set point of the Operatingregulator becomes less than the set pointof the Monitor regulator, the interstagepressure will rise to 2-4 PSI below the fullinlet pressure.

CHECKING STANDBY MONITOR OPERATION

1. With flow going through the station, slowlyincrease the setting of the Operating regulator.When the pressure reaches the setpoint of theMonitor Regulator, the Monitor should takecontrol and the interstage pressure shoulddecrease to approximately 2-4 PSI above theoutlet pressure.

2. Reduce the setting of the OperatingRegulator back to the required outlet pressure.The interstage pressure should increase to 2-4 PSI below the inlet pressure as theOperating Regulator regains control.

START UP AND OPERATION (Cont'd)

-14-

NOTES

NOTES

START UP AND OPERATION (cont'd)

WORKING MONITOR

1. Purge any pressure in the station.

2. Set Pilots #2 and #3 to a setting above thedesired set points.

3. Set the Monitor Pilot (#1) at a zero setting.

4. Slowly open the inlet block valve to station.The First Stage Regulator should remainclosed as a result of the Pilot #1 being set tozero.

5. Open an outlet valve or vent to allow flowthrough the station.

6. Increase the setting of the Monitor Pilot (#1)to the desired pressure setting.

7. Lower the setpoint of the Second StageRegulator Pilot (#3) to the desired outletpressure setting. The First Stage Regulatorshould open or begin to control the interstagepressure at the setpoint of Pilot #2.

8. Adjust the setpoint of Pilot #2 to achievethe desired interstage pressure.

9. Raise the setpoint of Pilot #3 to verify thesetpoint of the Monitor Pilot (#1). Adjust ifnecessary.

10. Return the setpoint of Pilot #3 to maintainthe desired outlet pressure.

-15-

2. Loosen and remove the Cap Screwssecuring the Actuator Housing and remove theActuator from the Body by lifting straight up.DO NOT PRY.

Fig. 6 Remove Actuator from Regulator Body3. Remove the Cage, Seat, Seat O-ring andBody Gasket. Inspect the Seat for damage. Ifany nicks, scratches, or other damage ispresent on the sealing surface (knife edge),the Seat must be replaced.

Fig. 7 Remove Cage, Seat, and O-ring

MAINTENANCE

Regulator parts are subject to normal wearand must be inspected and replaced asnecessary. The frequency of inspection andreplacement of parts depends on severity ofservice conditions or the requirements of local,state, and federal regulations. Be certain thatthe nameplates are updated to accuratelyindicate any field changes in equipment,materials, service conditions, or pressuresettings.

NOTE: The Regulator and Actuator havebeen designed to facilitate themaintenance of the major wearcomponents without the need tocompletely disassemble the Actuator.

PARTIAL DISASSEMBLY FOR STEM/PLUG/SEAT INSPECTION

1. Disconnect Actuator Control/Sense andPilot supply lines to the Actuator.

Fig. 5 FlowMax with tubing removed.

-16-

Before disassembly make sure theregulator has been isolated from theprocess by closing block valves on theinlet and outlet sides of the regulator.Safely release pressure and process fluidfrom the system. Failure to completethese steps can result in personal injuryand property damage.

Installation and testing of the FlowMaxRegulator should be made bytrained,qualified personnel familiar withhigh-pressure piping and Regulators.

CAGE

SEAT

O-RING

6. Remove the Stem Bushing from the bottomof the Lower Actuator Housing. Use cautionto not damage the sealing surface of the Stem.

Fig. 10 Removing the Stem Bushing

7. Inspect the Stem O-ring in the internalgroove of the Bushing for wear and/or damage.

Fig. 11 Inspecting the Stem O-ring

4. Remove the Lower Stem Nut and removethe Plug Assembly

NOTE: When removing or tightening theStem Nut, use a wrench on the Stem Flatsto prevent the Stem from rotating anddamaging the Main Actuator Diaphragm.

Fig. 8 Removing Plug Assembly from Actuator Stem

5. Inspect the Plug Seal and Plug O-ring fordamage or wear. If damaged, the Plug Sealmay be turned over or replaced.

Fig. 9 Inspecting the Plug Seal

MAINTENANCE (cont'd)

-17-

PLUGASSEMBLY

STEMFLATS

PLUGSEAL

STEMO-RING

STEMBUSHING

MAINTENANCE (cont'd)PARTIAL ASSEMBLY FOR STEM/PLUG/SEATINSPECTION

NOTE: Lightly lube O-rings beforeinstallation.

1. If the O-rings have been removed, reinstallthe Bushing O-ring and the Stem O-ring.

2. Screw the Stem Bushing into the bottomside of the Lower Actuator Housing until theBushing flange has bottomed on the housing.Do not over tighten.

3. Install a new O-ring in the internal Pluggroove.

Fig. 12 Inspecting the Plug O-ring4. Install the Plug onto the tapered end of theStem with the Plug Seal facing away from theActuator.

5. Screw the Stem Nut on the bottom of thestem with the rubber seal toward the Plug tolock the Plug Assembly in place. Use a wrenchto hold the stem while tightening the stem nut.

Fig. 13 Hold the Stem while tightening theStem Nut

-18-

6. Ensure that the Seat bore in the Body isclean and install the Seat O-ring and Seat intothe bore in the Body. Make sure that thechamfered edge of the Seat is resting againstthe Seat O-ring and that the knife-edge sealingsurface is facing up.

Fig. 14 Proper Seat Orientation

7. Install the Cage onto the Seat. The Cageshould fit snugly over the raised lip on theSeat. Do not damage the Seat sealing surfacewhen installing the Cage.

8. Install the Body Gasket.

Fig. 15 Installing the Body Gasket9. Line up the mounting holes in the Body withthose in the Lower Actuator Housing, andmake sure that the Loading Port in the LowerActuator Housing is facing towards the frontof the Regulator. Apply a light coating oflubricant to the Housing O-ring and lower theActuator Assembly onto the Body. Use cautionnot to pinch the Housing O-ring duringinstallation.

PLUG O-RING

PLUG GROOVE

BODYGASKET

SEAT

PLUG

Fig. 16 Installing the Main Actuator10. Incrementally tighten the Body Cap Screwsto specified torque values. Table 4 Page 26

NOTE: The gap between the Actuator andBody should be even. Approx. 1/16 in.

Fig. 17 Tightening the Body Cap Screws11. Reconnect Control/Sense and Pilot supplylines to the Actuator.

PARTIAL DISASSEMBLY FOR BALANCINGDIAPHRAGM INSPECTION

1. Disconnect Control/Sense and Pilot supplylines to the Actuator.

2. Loosen the Spring Case Cap and removethe Main Spring.

Fig. 18 Removing the Main Spring3. Remove the Spring Case Bolts, the SpringCase, and the Spring Case O-ring.

Fig. 19 Removing the Spring Case4. Loosen and remove the Cap Screwssecuring the Actuator Housing and remove theActuator from the Regulator Body by liftingstraight up. DO NOT PRY.

5. Remove the Upper Stem Nut located on topof the Piston. When removing the Upper StemNut, hold the Stem with a wrench at the Stemflats near the Plug Assembly. Failure to do somay cause damage to the Main ActuatorDiaphragm. Remove and inspect the Piston,Washer, and Balancing Diaphragm. Inspectthe Piston Ring and Balancing Diaphragm forsigns of wear and damage. Replace asnecessary.


-19-

UPPER STEM NUT

PARTIAL ASSEMBLY FOR BALANCINGDIAPHRAGM INSPECTION

1. Install the Balancing Diaphragm onto theBalancing Diaphragm Retainer. Ensure thatthe Diaphragm convolute is facing down. Onceinstalled, the top Diaphragm flange should beflush with the counter bore surface of theUpper Actuator Housing.

Fig. 20 Replacing the Balancing Diaphragm2. Install the Piston Ring onto the Piston.

Fig. 21 Installing Piston Ring on Piston3. Install the Piston onto the Stem with thePiston Ring and counter bore up. The bottomend of the Piston should fit over the BalancingDiaphragm and hold it in place over theBalancing Diaphragm Retainer.

Fig. 22 Installing Piston over Balancing Diaphragm

MAINTENANCE (cont'd)4. Install the Washer in the Piston counter boreand install the Upper Stem Nut. Use a wrenchto hold the Stem while tightening the UpperStem Nut.

Fig. 23 Installing the Washer in the Piston Counter bore5. Place the Balancing Diaphragm O-ring intothe counter bore in the Upper Actuator Housingand install the Spring Case onto the Housing.

NOTE: When installing the Spring CaseO-ring, it is recommended that the O-ringbe lightly stretched to ease assembly ofthe Spring Case on the 2" size only.

Fig. 24 Installing the Balancing Diaphragm O-ring6. Insert the Main Spring into the Pistoncounterbore and install the Spring Case Cap.

Fig. 25 Installing the Main Spring

-20-

BALANCINGDIAPHRAGMO-RING

PISTONRING

WASHERBALANCINGDIAPHRAGM

DISASSEMBLY FOR MAIN DIAPHRAGMINSPECTION

1. Disconnect Control/Sense and Pilot supplylines to the Actuator.

2. Loosen and remove the Cap Screwssecuring the Actuator Housing and removethe Actuator from the Body by lifting straightup. DO NOT PRY.

Fig. 28 Removing the Main Actuator3. Loosen the Spring Case Cap and removethe Main Spring.

4. Loosen the Spring Case Capscrews andremove the Spring Case.

5. Loosen the Upper Stem Nut and removethe Piston from the Stem. Remove theBalancing Diaphragm. Use a wrench to holdthe Stem while loosening the Stem Nut.

6. Loosen the Housing Cap Screws andremove the Upper Actuator Housing.

Fig. 29 Removing the Housing Cap Screws


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7. Lightly coat the Body/Actuator O-ring withlubricant and install the Body Gasket.

8. Line up the mounting holes for the Bodywith those in the Lower Actuator Housing,and make sure that the Loading port in theLower Actuator Housing is facing toward thefront side of the Regulator.

Fig. 26 Installing the Actuator on the Body.9. Lower the actuator assembly onto the valvebody. Use caution not to pinch the housing O-ring during installation.

10. Incrementally tighten the Body Cap Screwsto specified torque values. Table 4 Page 26

Fig. 27 Tightening the Body Cap Screws

NOTE: The compressed Gasket betweenthe Actuator and Body should be even.Approximately 1/16 in.

11. Reconnect Control/Sense and Pilot supplylines to the Actuator.

7. Remove the Balancing DiaphragmRetainer and inspect the Stem O-ring. Use awrench to hold the Stem while loosening theRetainer.

Fig. 30 Removing the Balancing DiaphragmRetainer

8. Remove the Upper Diaphragm Retainerand the Main Diaphragm. Inspect the MainDiaphragm for any damage.

9. Inspect the Main Diaphragm Stem O-ringsin the Upper and Lower Retainers fordamage and replace if necessary.

Fig. 31 Inspecting Stem O-ring

ASSEMBLY OF MAIN DIAPHRAGM1. Install the Main Diaphragm Stem O-ringinto the internal groove of the LowerDiaphragm Retainer with the Stem still inplace in the Lower Actuator Housing. Thegroove should be facing up. Install theRetainer on the stem.

Fig. 32 Installing Lower Diaphragm Retainer

2. With the Main Diaphragm convolute facingup, install the Diaphragm on the Stem untilthe Diaphragm is bottomed on the LowerDiaphragm Retainer.

3. Install the Upper Diaphragm Retainer overthe threaded end of the Stem so it is restingon the Main Diaphragm.

4. Install the Balancing Diaphragm Retainerover the Stem and tighten. Use a wrench tohold the Stem while tightening the Retainer.

5. Align the small hole in the Diaphragmflange with the Alignment Pin in the LowerActuator Housing and bottom the Diaphragmon the Housing flange.

Fig. 33 Diaphragm Alignment Pin


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RETAINER

STEMO-RING

ALIGNMENTPIN

6. Install the Upper Housing onto the LowerHousing and Diaphragm. Ensure that theAlignment pin engages the Alignment hole inthe Upper Housing.

7. To hold the assembly in place, install at leasttwo of the Housing Cap Screws on oppositesides of the Housing and tighten finger tight.

8. Move the Stem Assembly through full stroke.The Stem should move freely.

Fig. 34 Checking Stem for free movement9. Return the Stem to the extended position.Install the Balancing Diaphragm onto theBalancing Diaphragm Retainer. Ensure thatthe Diaphragm convolute is facing down. Thetop Diaphragm flange should be flush with thelower counter bore surface of the Housing.

10. Install the Piston Ring onto the Piston.

11. Install the Piston onto the Stem with thePiston Ring and counter bore up. The bottomend of the Piston should fit over the BalancingDiaphragm and hold it in place against theBalancing Diaphragm Retainer.

Fig. 36 Installing Piston on the Actuator Stem12. Install the Washer in the Piston counterbore and install the Stem Nut. Use a wrenchto hold the Stem while tightening the Retainer.

Fig. 37 Installing Washer on the Piston13. Place the Balancing Diaphragm O-ring intothe counter bore in the Upper Actuator Housingand install the Spring Case onto the Housing.Install the Spring Case Cap Screws.

NOTE: When installing the Spring CaseO-ring, it is recommended that the O-ringbe lightly stretched to ease assembly ofthe Spring Case on the 2" size only.


Fig. 35 Installing Balancing Diaphragm

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PISTON

WASHER

PISTON


Fig. 38 Installing the Balancing Diaphragm O-ring14. Move the Stem Assembly through fullstroke. Ensure that the Stem Assemblystrokes smoothly. Install and tighten theMain Actuator Housing Cap Screws.

NOTE: If the Stem Assembly does notstroke smoothly, the Stem Assembly mustbe realigned.

15. Install the remaining Actuator HousingCap Screws and tighten to appropriatetorque specifications. Table 4 Page 26

16. Insert the Main Spring and tighten theSpring Case Cap. Ensure the Spring is fullybottomed in the Piston counterbore.

Fig. 39 Installing the Main Spring17. Manually stroke the Actuator by pushingthe Stem/Plug against a hard surface toensure that the Stem Assembly moves freelythrough full stroke and that the Stem/Plug

returns to the extended position due to thespring force.

18. Inspect, clean, and install the Seat O-ring, Seat and Cage into the Body.

Fig. 40 Installing the Seat19. Install the Body/Actuator Gasket. Applya light coating of lubricant to the HousingO-ring.

20. Install the Actuator Housing onto theBody and incrementally tighten the mount-ing bolts.

Fig. 41 Installing the Actuator on Body

21. Replace tubing.

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TRAVEL INDICATOR KIT INSTALLATION(OPTIONAL)

An optional Travel Indicator Kit is availablefor the FlowMax regulator. Contained in thekit is an Indicator Stem, Indicator Stem O-ring,Indicator Stem O-ring Retainer, Spring CaseCap, Indicator Cover O-ring, and IndicatorCover. The following outlines the installationprocedures for the kit. A pre-drilled and tappedStem Nut currently exists as part of theFlowMax regulator and is not included in thekit.

Fig. 42 Travel Indicator Kit1. Remove the existing Spring Case Cap andSpring. Place a small amount of threadlocking compound on the Indicator Stemthreads. Finger tighten the Indicator Stem intothe Stem Nut until bottomed. Use caution tonot damage the Indicator Stem sealing surface.

Fig. 43 Installing the Indicator Stem into the Stem Nut2. Lubricate and insert the Indicator Stem O-ring into the small counterbore in the bottomof the new Spring Case Cap.


Fig. 44 Installing the Indictor Stem O-ring3. Install the threaded Indicator O-ring Retainerinto the Spring Case Cap until bottomed.Check to ensure the Indicator Stem O-ring isinstalled correctly and there is a visible holethrough the Cap.

Fig. 45 Installing the Oring Retainer4. Reinstall the Main Spring. Install the SpringCase Cap O-ring and lightly lubricate the O-ring and threads. Thread the Spring Case Caponto the Spring Case until bottomed.

Fig. 46 Installing the Spring Case Cap

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STEMO-RING

COUNTERBORE

5. Install the O-ring onto the Indicator Cover.Lightly lubricate the O-ring and threads.Screw the Indicator Cover into the SpringCase Cap until bottomed.

Fig. 47 Installing the Indicator Cover


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CLEANING

1. DO NOT clean O-ring grooves with sharpmetal tools. The bottom of the grooves musthave a smooth finish to prevent leakage. Themating surface of adjacent parts must also besmooth to prevent leakage.

NOTES

)TF-BL(SEUQROTGNITLOBxaMwolF

"2 "3 "4 "6

SWERCSPACGNISUOH 7-6 21-01 21-01 61-51

TUNMETS 8-7 01-8 21-01 21-01

ESACGNIRPS 6-5 7-6 7-6 01-8

TUNGULP 01-7 01-7 01-7 01-7

SWERCSPACYDOB 61-21 61-21 61-21 02-61

Table 4

WARRANTY

While the information in this manual is presented in good faith and believed to be accurate, Mooney Controls, Inc. does not guarantee satisfactoryresults from reliance on such information. Mooney Controls, Inc. reserves the right, without notice, to alter or improve the designs orspecifications of the products described herein.

SALT LAKE CITYUTAH

40 WEST GREGSON AVE.(801) 487-2225 SALT LAKE CITY, UTAH 84115

LIMITED WARRANTY: Seller warrants title and that thegoods manufactured by the Seller will be free fromdefects in materials and workmanship under normal useand service until the expiration of the earlier of twelve (12)months from the date of initial operation or eighteen (18)months from the date of shipment by Seller. Resalegoods shall carry only the warranty extended by theoriginal manufacturer to the original purchaser. If, withinthirty (30) days after Buyer's discovery of any warrantydefects, Buyer notifies Seller in writing, Seller shall, at itsoption, promptly repair or replace F.O.B. point of manu-facture, that portion of the goods found by Seller to bedefective. Goods repaired and parts replaced during the

warranty period shall be in warranty for the remainder ofthe original warranty period. This warranty is the onlywarranty made by Seller and can only be amended by awritten instrument signed by an officer of Seller. Subjectto this warranty and EXCEPT AS EXPRESSLY PRO-VIDED IN SALES LITERATURE, MOONEY CONTROLS,INC. MAKES NO REPRESENTATION OR WARRANTYOF ANY KIND, EXPRESS OR IMPLIED, AS TO MER-CHANTABILITY, FITNESS FOR PARTICULAR PUR-POSE, OR ANY OTHER MATTER WITH RESPECT TOANY OF THE PRODUCTS.

TROUBLESHOOTING

Regulator does not shut off

1. Check the Actuator to Bodyclearance.

2. Check Actuator to Body bolts -tighten if neccessary

3. Check for an open Pilot4. Check Main Spring5. Check the Plug Seal for damage6. Check the Seat for any nicks or

damage to the sealing surface7. Check for damage to the seat O-

ring8. Check for obstructions in the Stem

hole9. Check for failure of the Balancing

diaphragm10. Check for blockage of the internal

restrictor

Regulator will not open

- Check if any valves in the Sense lineare not fully open

- Check the Pilot set point- Check that existing piping matches the

piping schematics- Check for binding- Check the Main Diaphragm for

damage

Erratic Behavior

- Check the location of the Sense line(away from pipes, fittings, and otherturbulent locations)

- Check that the size of the Sense lineis adequate

- Check if any valves in the Sense lineare not fully open

- Check the Pilot for excess friction(“sticking”)

- Check for excess friction in theActuator

Documents

INSTALLATION / OPERATION / MAINTENANCE MANUAL FOR … Flowmax Manual.pdf · PAT. PENDING 730-091-01 Table 2 ... INSTALLATION / OPERATION / MAINTENANCE MANUAL FOR THE FlowMaxTM REGULATOR