Becker HPP-SB User manual

Section Page
Introduction 2
Scope of Manual 2
Description 2
Technical Information 3
Specifications 3
Materials of Construction 3
Accessories 3
Principals of Operation 4
Close on increasing 4
Open on increasing 5
Adjustment Procedure 6
Deadband Setting 6
Bias Adjustment 7
Range Adjustment 8
Instruction Manual
for
the HPP-SB
High Pressure
Single-Acting Positioner
Table of Contents
Section Page
Changing Positioner Action 9
Conversion to Split Range 10
Assembly Procedures 14
Inspection Procedures 17
Parts Ordering 18
Parts List 18
Seal Kits 18
Appendix –Parts & Mounting detail
Feedback detail 19
Open on increasing (parts) 21
Close on increasing (parts) 22
Open on Incr., L, R 23,24
Close on Incr., L, R 25,26
HPP-SB September 1999

HPP-SB Positioner
Instruction Manual
Introduction
The Becker HPP-SB series balanced seat de-
sign, single acting positioner represents a
breakthrough in valve control technology for the
natural gas industry. Built to exacting specifica-
tions, this easily maintained unit offers highly
accurate control characteristics over a wide
range of operating environments. The HPP-SB
eliminates atmospheric emissions when the
control valve is in a full closed standby position;
when it is in a full open monitor position; or
when it is controlling in a steady-state condi-
tion. Furthermore, the HPP-SB series positioner
is designed to allow bleed gas to be routed to a
lower pressure system, or downstream, for
complete elimination of bleed gas. The elimina-
tion of this expensive bleed gas ultimately
saves a significant amount of money for the op-
erating company and reduces the environ-
mental impact of atmospheric hydrocarbons
and diminishing natural resources.
Description
The Becker HPP-SB positioner is used to pro-
vide extremely accurate pressure control in con-
trol valve assemblies utilizing a controller or I/P
transducer and single-acting actuator. The
HPP-SB is designed for use with ball valves
16”* in diameter or smaller (when used with
Becker single-acting control valves).
*Valves over 16” in diameter require the use of
volume boosters.
Scope of Manual
This manual provides information on the instal-
lation, operation, adjustment, and maintenance
of the HPP-SB positioner. For information con-
cerning actuators, valves, and accessories, re-
fer 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, 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: [email protected]
Website: www.bpe950.com
HPP-SB 2September 1999

Maximum Supply Regulator Capacity
Q = Min. Supply Regulator Capacity
(scfh)
G= Specific Gravity of Gas
T= 460 + Operative Temperature (°F)
Cv = Flow Factor (1.5 for HPP-SB)
P1= Supply Pressure to Positioner (psig)
Accessories
•Atmospheric Bleed Control (AB Control):
maintains minimum pressure differential
across the cylinder. The AB Control is re-
quired in order to provide the necessary
output to operate the control valve under all
design conditions.
•Quick Exhaust Valve: purges high volumes
of gas from the actuator when there is a
need for an unusually quick response.
Input Signal: Standard: 3-15 psi or 6-30 psi.
Adjustable: Zero is adjustable from 2-30
Output Signal: Pneumatic pressure as required by the
Loss of Signal: Reverse Acting: Open on loss of signal.
Connections: P1, P2, P3, P4: ½” N.P.T.
Action: Direct and Reverse Acting:. Field-
reversible
Performance: Resolution: 0.4%*
Flow Capacity: CV= 1.5
Steady State Zero.
Power Gas Require-
ment: Use clean, dry filtered (100 micron) gas.
Discharging to Atmosphere:
150 psig maximum.
Discharging to Pressure System: 400
Operative Temperature
Limits: -20 to 160°F
(-28 to 70°C).
Housing: Meets NEMA 3 classification (weather
tight).
Installation Orientation: Vertical or horizontal position allowable.
Approximate Weight: 15 pounds.
External Parts: Anodized 2024 Aluminum
Internal Parts: 316 Stainless Steel and 2024 Ano-
dized Aluminum
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-
nection with Stainless Steel Case.
(Stainless Steel connection op-
HPP-SB Positioner
Specifications
Technical Specifications Materials of Construction
*Performance figures for resolution and repeatability reflect those of
a positioner adjusted with a minimum deadband for reduction of
bleed gas. If the deadband is eliminated, bleed gas will increase
slightly and resolution and repeatability will improve.
HPP-SB 3September 1999
Q = 312.86 xP1x CVx
)( 460
1
+× TG

The positioner is a force-balanced instru-
ment that provides a control valve position pro-
portional to a pneumatic input signal. The con-
trol valve will open on loss of input signal. The
energy to operate the control valve is obtained
from the differential between the force created
by the pneumatic loading of one side of the
cylinder and the opposing spring
(encapsulated in the actuator spring car-
tridge). In steady-state, the force imposed on
the balance beam by the input signal dia-
phragm and the range spring are equal.
Therefore, the top and bottom balance valves
of the positioner will be at their closed posi-
tions. The positioner does not feed gas to the
cylinder or exhaust the loading pressures from
the cylinder. When the spring force and cylin-
der force are equal, the control valve remains
stationary.
HPP-SB Positioner
“How-It-Works”
An increase in the input signal pressure re-
sults in the opening of the lower balanced
valve due to an imbalance in the beam forces.
This increases the pressure in the cylinder,
further closing the valve and compressing the
actuator spring. The actuator feedback rod
stretches the range spring, increasing its ten-
sion. 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 when the actuator
spring and cylinder forces again balance. The
sensitivity adjustment of the positioner
changes the positioner’s deadband (the
change in input signal necessary to create a
certain amount of change in output signal).
Principles of Operation
Close on Increasing Signal –Actuator Fails Open
HPP-SB 4September 1999

The control valve will close on loss of input
signal. The energy to operate the control valve
is obtained from the differential between the
force created by the pneumatic loading of one
side of the cylinder and the opposing spring
(encapsulated in the actuator spring cartridge).
In steady-state, the forces imposed on the bal-
ance beam by the input signal diaphragm and
the range spring are equal. Therefore, the top
and bottom balance valves of the positioner will
be in their closed positions. The positioner does
not feed gas to the cylinder or exhaust loading
pressures from the cylinder. When the spring
force and cylinder force are equal, the control
valve remains stationary.
An increase in the input signal pressure re-
sults in the opening of the upper balanced valve
(due to an imbalance in the beam forces).
HPP-SB Positioner
“How-It-Works”
This increases the cylinder pressure, further
opening the valve and compressing the actua-
tor spring. The actuator feedback rod retracts,
stretching the range spring, and increasing its
tension. This force, which opposes the force
on the balanced beam (caused by the increas-
ing input signal) continues to increase until the
balance beam forces are in equilibrium. The
valve is in the correct position for the applied
input signal when the actuator spring and cyl-
inder forces balance.
The sensitivity adjustment of the posi-
tioner changes the positioner’s deadband (the
change in input signal necessary to create a
certain amount of change in output signal).
HPP-SB 5September 1999
Open on Increasing Signal –Actuator Fails Closed

Your HPP-SB series positioner will arrive
factory adjusted for your particular application.
The use of the following adjustment proce-
dures will only be necessary once a rubber
goods replacement kit is installed or any other
time the positioner is disassembled.
Adjustment Procedure
The Becker HPP-SB Positioner has three (3)
adjustment devices:
•The adjustment drum adjusts the dead-
band.
•The range spring adjusts the span.
•The adjustment screw adjusts the bias.
Note: Before making any adjustments, be
sure the positioner supply pressure and dis-
charge pressure are at the designated set-
tings.
HPP-SB Positioner
Adjustment
5. If the actuator is equipped with an MCV-3
Manual Control Valve), place the left MCV-
3 handle in the manual position. If the ac-
tuator is not equipped with an MCV-3, use
the block valve (1/4 “ ball valve) installed
between the positioner output and the ac-
tuator. Once the actuator has reached its
desired position (based on the mid-signal
applied to the instrument port –Step 4),
place the block valve in the closed posi-
tion.
6. Check the exhaust port of the positioner
(remove any tubing if necessary). If ex-
haust port bleeds gas, turn the adjustment
drum (decreasing numbers) until the ex-
haust port stops bleeding gas. If the ex-
haust port does not bleed gas, turn the ad-
justment drum (increasing numbers) until
the exhaust port starts to bleed gas and
then back the drum off slightly until the
point in which it just stops bleeding. After
each adjustment, fluctuate the input signal
to allow output pressure to swing in both
directions.
Deadband Setting
1. Remove the set screw from the drum and
turn the deadband adjustment drum
(increasing the numbers) until the drum
can no longer turn. Then turn the adjust-
ment drum one full turn in the opposite di-
rection (use the numbers on the drum as a
guide).
2. If not already attached, wind 3-4 coils of
the range spring onto the retainer.
3. If not already adjusted, set the bias adjust-
ment screw in the middle of its travel
range.
4. Set the instrument signal pressure at the
midpoint of its range (e.g.. 9 psig for a 3-15
psig range, 18 psig for a 6-30 psig range).
Stroke the actuator to an intermediate po-
sition.
7. The unit is properly adjusted if an increase
or decrease in the input signal by .1 psig
causes the output gauge to swing in either
direction.
Signal Line from Control-
HPP-SB 6September 1999

HPP-SB Positioner
Adjustment
Bias Adjustment
The bias, or offset, determines the input
signal at which the positioner begins to stroke
the valve. Give the positioner an input signal
equal to the low value of the input range
(usually 3 or 6 psig). The bias lock nut(s)
must be loosened before adjustment.
Span Adjustment
Spring Lock
Balanced Beam
Proportional Topworks
Bias Lock Nuts (Qty. 2)
Spring Retainer
Bias Adjustment
Note: When increasing or decreasing the in-
strument signal, the output pressure should
swing up and down. When changing direction
of the false instrument signal, the output pres-
sure should immediately reverse direction.
Any “bump” or initial reaction of the gauge in
the wrong direction indicates friction (requiring
the unit be rebuilt to eliminate the friction).
8. Replace the exhaust port fitting.
Step 9 for units bleeding to a pressure system
ONLY:
9. Turn the adjustment drum one division (¼
of a number, NOT one full number) in the
direction of increasing numbers. Re-attach
exhaust port to pressure system.
For Standard (Non-split range) Systems:
1. To increase the bias setting, increase ten-
sion on the range spring. This is accom-
plished by either raising the spring retainer
or screwing the bias adjustment stud into
the indicator bar or tail rod. Note the two
jam nuts tightened against one another to
adjust the length of the stud. When prop-
erly adjusted, tighten the bias lock nut(s).
2. In order to decrease the bias setting, de-
crease tension on the range spring by ei-
ther lowering the spring retainer or screw-
ing the bias adjustment stud out of the in-
dicator bar or tail rod. Note the two jam
nuts tightened against one another to ad-
just the length of the stud. When properly
adjusted, tighten the bias lock nut(s).
For Split Range Systems (see Table 1 below):
3. Find the bias adjustment screw (1/2-20
thread with 3/8 flats) on the end of the po-
sitioner opposite the pneumatic signal in-
put port. Loosen the jam nut located on
the adjustment screw.
4. To increase the bias setting, tighten the
adjustment screw.
5. To decrease the bias setting, loosen the
adjustment screw.
6. Holding the adjustment screw in place,
tighten the jam nut against the positioner
body.
If there is no gauge response, the deadband
must be decreased by turning the adjustment
drum slightly (increasing numbers). Re-check
the deadband.
HPP-SB 7September 1999
Spring Range
Green (20-2592) 1-6
Silver (25-1038) 2-11
Blue (25-1036) 4-20
Red (25-1037) 8-30
Table 1: Adjustable Bias Springs

Range Adjustment
Note: There will be some interaction between
range and bias adjustments. It may therefore
be necessary to readjust the bias and re-check
the range after completing the following steps.
The range, or the amount of travel between the
lower and upper limits of the input signal, is set
with the range spring. This range will typically
be 12 psi for a 3-15 psi system or 24 psi for a 6-
30 psi system. The limits of the range can be
defined as the initial point at which the instru-
ment signal to the HPP-SB creates full (equal
to the power gas pressure) or zero (depending
on the positioner and actuator action) output
pressure.
1. After setting the bias for the start of the valve
travel, continue increasing the instrument
signal until full stroke of the valve is
achieved.
2. The upper end of the range will be found
when the valve travel indicator reaches the
end of stroke AND the output pressure
gauges read full power gas or zero
(depending on the positioner and actuator
action). Be sure not to overshoot at this
point as any signal level above this upper
limit will show the same reading on the cyl-
inder gauges. This point is the highest end
of the range and the value may not neces-
sarily be equal to the desired upper range
HPP-SB Positioner
Adjustment
3. If the range is less than desired (i.e. the
actuator reaches its full travel in less than
the specified input range), strengthen the
range spring by winding it counterclock-
wise onto the spring retainer.If the range
is greater than desired, weaken the range
spring by winding it clockwise. Repeat
adjustments until the desired range pro-
vides full or zero output pressure.
4. If the desired range is not achieved after
making the above adjustments, readjust
the bias (per the previous instructions) to
allow proper range adjustment.
5. It may be necessary to change the range
spring retainer for some non-standard
ranges (refer to Table 3).
HPP-SB 8September 1999
Note: For intermediate ranges, use the next size range spring.
Stroke (Part Number)
46812
601-6288 01-6287 01-6287 01-6801
12 25-1151 25-1152 25-1153 25-1154
18 25-1599 25-1600 25-1601 25-1602
24 25-1218 25-1219 25-1220 25-1221
Spring Range
(psi)
Table 2: Range Spring Configurations
Table 3: Range Spring Retainer
Type Typical Use
Short (01-2509 ) 8” and 12” Stroke
Intermediate (11-2572 ) 6” Stroke
Long ( 01-2042 ) 4” Stroke

Changing Action of Positioner
To change the positioner from open on in-
creasing signal to close on increasing signal,
or vice versa, the following parts kits must be
ordered:
To change open on increasing to close on in-
creasing: Part #25-1444 plus an Extension
Rod (item #13 in drawing 35-0516, see Table
4). The serial number of the actuator must be
specified. The exact part number of the exten-
sion rod will vary based on the actuator stroke.
To change close on increasing to open on in-
creasing: Part #25-1289. Note: If converting
a close on increasing signal positioner to open
on increasing signal, the wide end of the tube
(item #9) may be shortened by 11/16" with a
hack saw in place of ordering part #25-1289.
The stroke length of the actuator cylinder
MUST be specified when ordering the above
part numbers. If the actuator serial number
cannot be found, the stroke length can be
found in the regulator model number. The
stroke length is the first letter after the "H" in
the model number. For example model
10H12L6FG-SR-S-HSB-40/35-100-O has a
stroke length of "L", or 12 inches ["L" is the
12th letter in the alphabet]).
Refer to the drawings 35-0515 and 35-0516 in
the Appendix for the following:
1. Disconnect all supply lines, instrument
line, and output line from the positioner.
2. Remove the range spring (item #4) at both
ends and those items connecting it to the
rod (item #23) and the positioner feedback
arm.
HPP-SB Positioner
Reversing Action
3. Remove the positioner from the bracket
(item #18). The tubing and fittings on each
side of the positioner must be taken off
and installed in the opposite corner from
their original position (see piping sche-
matic provided by Becker Precision Equip-
ment) then reattached to the positioner.
This will allow the positioner to maintain
the actuator failure mode when the posi-
tioner is turned upside down.
4. Move the bracket assembly (item #18),
tube assembly (items #16 and #17), and
cover plate (item #11) to the positions
shown on the desired drawing.
5. Install the positioner in the opposite of its
original position (upside down if it was
right side up, right side up if it was upside
down).
6. Using parts from the factory kit, assemble
the spring and surrounding hardware ac-
cording to the drawing of the desired con-
figuration. (Note: all original parts may not
be used when converting from close on in-
creasing to open on increasing).
7. The entire bracket assembly (item #18) or
the outer angle may need to be turned up-
side down to accommodate the new spring
height.
8. Reconnect the supply, instrument, and out-
put lines according to piping schematic
supplied.
Note: The flow direction must be maintained
through the positioner bodies when re-piping.
(I.e. the flow [supply or exhaust] moves from
P1 to P2 and P3 to P4).
HPP-SB 9September 1999

Conversion to Split Range
Converting a standard positioner to a split
range positioner (pneumatic input other than
3-15 psi or 6-30 psi), requires ordering the
proper conversion kit from the factory. This kit
will include a bias spring and bias spring car-
tridge. If required, it will also contain a new
range spring and mounting spacers.
1. For close on increasing positioner:
Remove the cap on the top of the posi-
tioner along with the spring inside it.
For open on increasing positioner:
Remove the mounting bracket holding the
cap on the bottom of the positioner. Then
remove this cap along with the spring in-
side it.
2. Replace the cap and spring with the larger
bias spring cartridge and bias spring
found in the kit. Make sure the bias ad-
justment screw in the bias spring car-
tridge is snug against the bias spring and
the spring is centered before tightening the
spring cartridge.
3. For open on increasing positioner:
Remove the washer and jam nut from the
adjusting screw in the bias spring car-
tridge. Reattach the mounting bracket up-
side down from its original position.
HPP-SB Positioner
Split Range
Stroke Close on
Increasing Open on Increasing Reference Drawings
4” 25-6014 25-1464 Proportional:
35-0513
35-0313/A
35-0511
35-0511/A
Tailrod Mount:
35-0533
6” 25-6014 25-1465 Proportional:
35-0522
35-0529
8” 25-6014 25-1466 Tailrod:
Table 5: Split Range Conversion Kits
Note: Refer to Table 1 and Table 2 for Bias
and Range Spring
Stroke With
Transmitter Without Transmitter
425-8265 25-8001
625-8136 25-1093
825-1402 25-1423
Table 4: Extension Rods for Positioners to
Close on Increasing Signal
Slide the thread spacer (brass bushing)
over the adjusting screw and tighten the
washer and jam nut against the thread
spacer.
4. If a range spring was sent with the kit, re-
move the existing range spring and replace
it with the new one.
5. Adjust the unit per the Adjustment Proce-
dures.
HPP-SB 10 September 1999