Becker HPP-5 Instruction Manual

Instruction Manual

for

the HPP-5

High Pressure

Positioner

Table of Contents

Section Page
Introduction 2
Description 2
Scope of Manual 2

Technical Assistance 2
Applications 3
Guidelines for usage 3

Technical Information 4
Specifications 4
Materials of Construction 4

Accessories 4
Principals of Operation 5

Close on increasing 5

Open on increasing 6
Adjustment Procedure 7

Deadband Setting 8

Bias Adjustment 9

Range Adjustment 10

Section Page
Changing Positioner Action 12

Conversion to Split Range 13
Assembly Procedures Separate Manual

Inspection Procedures 15

Parts Ordering 16
Parts List 16

Seal Kits 16
Appendix – Parts & Mounting detail

Open on increasing (parts) 18
Close on increasing (parts) 19

HPP-4 Positioner
Instruction Manual

Introduction

The Becker HPP-5 series positioner
represents a breakthrough in valve con­trol technology for the natural gas in­dustry. Built to exacting specifications,
the easily maintained unit offers highly
accurate control with excellent control
characteristics in a broad range of oper­ating environments. The HPP-5 series
positioner is designed such that upon
reaching a valve position and achieving
a steady state, the gas consumption is
very low. Additionally, its bleed gas
can be routed to a lower pressure
downstream or fuel gas system, elimi­nating bleed gas completely. This
means significant savings to your com­pany in terms of minimizing expensive
bleed gas as well as a cost saving
means of minimizing the environmental
impact of atmospheric hydrocarbons
and diminishing natural resources.

Description

The Becker HPP-5 positioner is used in
control valve assemblies with a control­ler or I/P transducer and double acting
actuator to provide accurate flow or
pressure control. The HPP-5 can be
used with various valve types that utilize
a double acting pneumatic piston ac­tuator. The HPP-5 design positioner
represents Becker’s commitment to
continuos development of new products
and updating of existing products to
maximize their performance while re­taining simple operation and minimum
maintenance.

Valves over 16” in diameter require the
use of a Becker HPP-4 positioner with
Volume boosters.

Scope of Manual

This manual provides information on in­stallation, operation, adjustment, and
maintenance of the Becker HPP-5 po-
sitioner. For information concerning ac­tuators, valves, and accessories, refer
to the instruction manuals provided with
the specific product.

Note: Only those qualified through training or
experience should install, operate, or maintain
Becker positioners. If there are any questions
concerning these instructions, contact your
Becker sales representative, sales office, or
manufacturer before proceeding.

Technical Assistance

Should you have any questions, you
may contact your local Becker Preci­sion sales representative or Becker
Precision technical assistance at:

Becker Precision Equipment, Inc.

Attn: Technical Assistance
950 Pratt Boulevard
Elk Grove Village, IL 60007 USA

Toll Free: [phone]
Tel: [phone]
Fax: [phone]
e-mail: [e-mail]

HPP-5 2 September 1999

HPP-5 Positioner
Instruction Manual

Applications

• Primary Pressure Control

• Overpressure Protection (Monitor)

• Underpressure Protection

(Standby)

• Relief Valve

• Backpressure Control

• Power Plant Type Applications*

• When Unique "Bleed to Pressure

System" BPS™ feature can be
utilized

• Any large downstream systems
(city gate stations, inter-system
pressure limiting)

• Suction control to reciprocating
compressors*

• Double-stage cut (working moni­tor regulator*

* (consult Becker for additional information)

Guidelines for Usage

Large Volume Control Valve Actuators:
Control Valves that require large volume
actuators may require Model VB-250
Volume Boosters to ensure adequate
stroking speed. HPP-5 positioners are
NOT compatible with volume boosters.
The HPP-4 positioner must be used

Bleed to Pressure System: The HPP-5
Positioner is typically utilized for applica­tions where no discharge pressure of
less than 350 psig is available. The very
low steady state bleed of the positioner
makes it efficient for minimizing atmos­pheric emmisions. The HPP-5 is also
compatible with the Becker BPS (Bleed
to pressure system).

High Gain Systems: The HPP-5 is not
preferred for this application. It may be
successfully used with small diameter
(4” and smaller) ball valves for this appli­cation, but its limited orifice capacity
makes it too slow for controlling larger
valves on short systems.

CVE Globe Pattern Control Valves: The
Becker HPP series positioners are com­patible with the Globe style control valve,
but require a minimum of 2” of actuator
stroke for proper feedback and opera­tion. This makes it impossible to use
this positioner with most globe valves
smaller than 4” port size.

Compatible Actuators:

• Becker RPDA Actuators (Rotary Pis-

ton Double-Acting)

• Becker LPDA Actuators (Linear Pis-

ton Double-Acting)

• Other manufacturer’s double-acting

piston actuators*
*consult Becker for additional informa-

tion

Retrofit Compatibility:

Optimum performance is achieved by
pairing the HPP-5 with genuine Becker
control valve actuators. Should you al­ready have existing control valve actuator
(s) in service, the addition of a Model
HPP-5 can improve performance and
eliminate atmospheric bleed emissions if
using the BPS (Bleed to a pressure sys­tem) feature.
Some Compatible Actuators:

• Bettis T-Series Piston Actuators

• Fisher Type 470 Piston Actuators

• Fisher Type 1061 Piston

HPP-5 3 September 1999

HPP-5 Positioner

Specifications

Technical Specifications

Input Signal: Standard: 3-15 psi or 6-30 psi.

Output Signal: Pneumatic pressure as required by the

Loss of Signal: Reverse Acting: Open on loss of signal.

Connections: All Ports: ¼” N.P.T.

Action: Direct and Reverse Acting:. Field-

Performance: Resolution: 0.4%*

Flow Capacity: CV = 1.5

Steady State
Consumption:

Power Gas Require­ment:

Operative Temperature
Limits:

Housing: Meets NEMA 3 classification (weather

Installation Orienta­tion:

Approximate Weight: 15 pounds.

Adjustable: Zero is adjustable from 2­30 psig, span is adjustable from 5-24

actuator up to full supply pressure.

Direct Acting: Close on loss of signal.

reversible

Hysteresis: .6%*

Near Zero

Use clean, dry filtered (100 micron)
gas.
Discharging to Atmosphere:
150 psig maximum.

-20 to 160°F
(-28 to 70°C).

tight).

Vertical or horizontal position allow­able.

Materials of Construction

External Parts: Anodized 2024 Aluminum
Internal Parts: 316 Stainless Steel and 2024 Ano-
Feedback Lever: 316 Stainless Steel

Range Spring: Plated Music Wire

Diaphragms: Buna-N with Nylon Reinforcement

Seats and O-Rings: Buna-N
Tubing: 316 Stainless Steel

Fittings: 316 Stainless Steel

Gauges: 2 ½” Dial Liquid filled Brass Con-

Maximum Supply Regulator Capacity

Q = 312.86 x P1 x CV x

Q = Min. Supply Regulators Capacity (scfh)
G = Specific Gravity of Gas
T = 460 + Operative Temperature (°F)

Cv = Flow Factor
P

= Supply Pressure to Positioner (psig)

1

dized Aluminum

nection with Stainless Steel Case.
(Stainless Steel connection op-

1

+× TG

460

)(

* Resolution and repeatability figures reflect a
positioner that is adjusted with a minimum dead­band to reduce bleed gas. If the deadband is
eliminated (slightly increasing the bleed gas),
resolution and repeatability will improve.

Accessories

• Atmospheric Bleed Control (AB Control):
maintains minimum pressure differential
across the cylinder. The AB Control is re­quired in order to provide the necessary
output to operate the control valve under all
design conditions.

• NBV No Bleed valve – same function as
DPS, no adjustments or tubing required.
Works up to 150 psig power gas.

• DPS Series Non-Bleed Sensor: achieves
non-bleeding conditions in either full open
or full closed positions. Selection based
upon power gas pressure and discharge
gas pressure.

HPP-5 4 September 1999

HPP-5 Positioner

“How-It-Works”

Power
Gas

Instrument­Signal

Cylinder
Top

Exhaust

Principles of Operation

Close on Increasing Signal

The positioner is a force-balanced instrument that provides a control valve posi­tion proportional to the pneumatic input signal. The control valve will open on loss
of input signal. The energy to operate the control valve is obtained from the differen­tial between the supply and discharge pressures. In steady state, the forces im­posed on the balance beam by the input signal diaphragm and the range spring are
equal; therefore, the top and bottom balance valves in the positioner are at or near
their closed positions. The cylinder top and bottom pressures are both equal to
power gas pressure, and the control valve is stationary. An increase in the input
signal pressure results in the opening of the lower balanced valve due to an imbal­ance in the beam forces. This decreases the pressure in the cylinder top., while
the pressure in cylinder bottom remains at power gas. The control valve begins to
close. The actuator rod stretches the range spring, increasing its tension. This
force, which opposes the force on the balanced beam caused by the increasing in­put signal, continues to increase until the balance beam forces are in equilibrium.
At this point the valve is in the correct position for the applied input signal. The po­sitioner has a sensitivity adjustment which permits a balance between greater ac­curacy (from a smaller deadband) and minimal bleed gas.

HPP-5 5 September 1999

HPP-5 Positioner

“How-It-Works”

Power
Gas

Instrument­Signal

Cylinder
Top

Exhaust

Open on increasing Signal

The positioner is a force-balanced instrument that provides a control valve posi­tion proportional to the pneumatic input signal. The control valve will close on loss of
input signal. The energy to operate the control valve is obtained from the differential
between the supply and discharge pressures. In steady state, the forces imposed
on the balance beam by the input signal diaphragm and the range spring are equal;
therefore, the top and bottom balance valves of the positioner are at or near their
closed positions. The cylinder top and bottom pressures are both equal to power
gas, and the control valve is stationary. An increase in the input signal pressure re­sults in the the opening of the upper balance valve due to an imbalance in the beam
forces. This decreases the pressure in the cylinder bottom, while the pressure in
the cylinder top remains at power gas pressure. The control valve begins to open.
The actuator rod stretches the range spring, increasing its tension. This force, which
opposes the force on the balanced beam caused by the increasing input signal, con­tinues to increase until the balance beam forces are in equilibrium. At this point the
valve is in the correct position for the applied input signal. The positioner has a sen­sitivity adjustment which permits a balance between greater accuracy (from a
smaller deadband) and minimal bleed gas.

HPP-5 6 September 1999