GE Becker HPP-5 Manual

GE Oil & Gas
GE Data Classification : Public
HPP-5
High Pressure Positioner
Installation and Maintenance Manual

1 | GE Oil & Gas © 2014 General Electric Company. All rights reserved.
Table of Contents
Introduction �����������������������������������������������������������������������������������������������������������������������������������������������������������������������������1
Description ������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 1
Scope of Manual ��������������������������������������������������������������������������������������������������������������������������������������������������������������������1
Technical Assistance
Applications ����������������������������������������������������������������������������������������������������������������������������������������������������������������������������2
Guidelines for usage �����������������������������������������������������������������������������������������������������������������������������������������������������������2
Technical Information
Specifications �������������������������������������������������������������������������������������������������������������������������������������������������������������������������2
Material of Construction����������������������������������������������������������������������������������������������������������������������������������������������������2
Accessories�������������������������������������������������������������������������������������������������������������������������������������������������������������������������������3
Principles of Operation ������������������������������������������������������������������������������������������������������������������������������������������������������3
Close on Increasing��������������������������������������������������������������������������������������������������������������������������������������������������������������3
Open on Increasing��������������������������������������������������������������������������������������������������������������������������������������������������������������4
Adjustment Procedure �������������������������������������������������������������������������������������������������������������������������������������������������������4
Deadband Setting�����������������������������������������������������������������������������������������������������������������������������������������������������������������5
Bias Adjustment ��������������������������������������������������������������������������������������������������������������������������������������������������������������������6
Range Adjustment
Changing Positioner Action ���������������������������������������������������������������������������������������������������������������������������������������������6
Conversion to Split Range ������������������������������������������������������������������������������������������������������������������������������������������������7
Parts Ordering �����������������������������������������������������������������������������������������������������������������������������������������������������������������������8
Parts List �����������������������������������������������������������������������������������������������������������������������������������������������������������������������������������8
Seal Kits ������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������8
Appendix – Parts & Mounting detail
Open on Increasing (parts) ����������������������������������������������������������������������������������������������������������������������������������������������9
Close on Increasing (parts) ����������������������������������������������������������������������������������������������������������������������������������������������9
Assembly Procedure ��������������������������������������������������������������������������������������������������������������������������������������������������������� 12
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 maintainable unit offers highly
accurate control with excellent control characteristics in a broad
range of operating environments� The HPP-5 series positioner is
designed so that when it reaches a valve position and achieves
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 because it limits expensive bleed gas and
decreases the environmental impact of atmospheric hydrocar-
bons on 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 positioner
can be used with various valve types that use a double acting
pneumatic piston actuator� The HPP-5 positioner represents GE’s
commitment to continuous development of new products and
updating of existing products to boost their performance while
retaining simple operation and limited 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 positioner�
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 you have
anyquestions concerning these instructions, contact your GE
representative before proceeding�

Becker HPP-5 High Pressure Positioner Maintenance and Operation Manual | 2© 2014 General Electric Company. All rights reserved.
Technical Assistance
Should you have any questions, you may contact your local GE
representative�
Applications
n Primary Pressure Control
nOverpressure Protection (Monitor)
n Underpressure Protection (Standby)
n Relief Valve
n Backpressure Control
n Power Plant Type Applications*
n When unique “Bleed to Pressure System” BPS™feature can
be used
n Any large downstream systems (city gate stations, inter-
system pressure limiting)
n Suction control to reciprocating compressors*
n 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 (BPS): The HPP-5 positioner is typically
used 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 reducing atmospheric emissions�
The HPP-5 positioner is also compatible with the Becker BPS�
High Gain Systems: The HPP-5 positioner is not preferred for this
application� It may be successfully used with small diameter (4
inch and smaller) ball valves for this application, but its limited
orifice capacity makes it too slow for controlling larger valves�
CVE Globe Pattern Control Valves: The Becker HPP series position-
ers are compatible with globe style control valves, but require a
minimum of 2 inches of actuator stroke for proper feedback and
operation�
This makes it impossible to use this positioner with most globe
valves smaller than 4 inch port size�
Compatible Actuators:
n
Becker RPDA Actuators (Rotary Piston Double-Acting)
n
Becker LPDA Actuators (Linear Piston Double-Acting)
n
Other manufacturer’s double-acting piston actuators*
*Consult GE for additional information
Retrofit Compatibility:
Excellent performance is achieved by pairing the HPP-5 positioner
with genuine GE control valve actuators� Should you already
have existing control valve actuator(s) in service, the addition of a
Model HPP-5 positioner can improve performance and eliminate
atmospheric bleed emissions if using the BPS (Bleed to Pressure
System) feature�
Some Compatible Actuators:
n Bettis T-Series piston actuators
n Fisher Type 470 piston actuators
n Fisher Type 1061 piston
Technical Specifications
Input Signal Standard:
Adjustable:
3-15 pis or 6-30 psi
Zero is adjustable from
2-30 psig, span is adjustable
from 5-24
Output Signal Pneumatic pressure as required
by the actuator up to full supply
pressure
Loss of Signal Direct Acting:
Reverse Acting:
Open on loss of signal
Close on loss of signal
Connections All Ports: 1/4 inch N�P�T�
Actions Direct Acting:
Reverse Acting:
Field-reversible
Field-reversible
Performance Resolution: 1%*
Hysteresis: 0�5%*
Flow Capacity CV= �1
Steady State Gas Consump-
tion
Near zero flow capacity
Power Gas Requirement
Discharge to Atmosphere:
Dry, filtered (100 micron) gas
150 psig maximum
Operative Temperature
Limits
-20°F to 160°F
(-28°C to 70°C)
Housing Meets NEMA3 classification
(weather tight)
Installation Orientation Vertical or horizontal position
allowable
Approximate Weight 15 pounds
*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�
Materials of Construction
External Parts Anodized 2024 Aluminum/316 SS Available
Internal Parts 316 SS and Anodized 2024 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
Guages 2-1/2 inch Dial Liquid Fi lled Brass Connection
with Stainless Steel Case (Stainless Steel
Connection Option)
Maximum Supply Regulator Capacity
Q = 312�86 x P1x CVx 1
G x (T + 460)
Q = Min� Supply Regulators Capacity (scfh)
G = Specific Gravity of Gas
T = Operative Temperature (°F)
CV= Flow Factor
P1= Supply Pressure to Positioner (psig)

3 | GE Oil & Gas © 2014 General Electric Company. All rights reserved.
Accessories
nAtmospheric Bleed Control (AB control): Maintains minimum
pressure differential across the cylinder� The AB control is
required to provide the necessary output to operate the control
valve under all design conditions�
nNBV No Bleed Valve: Same function as DPS, no adjustments or
tubing required� Works up to 150 psig power gas�
nDPS Series Non-Bleed Sensor: Achieves non-bleeding condi-
tions in either full open or full closed positions� Selection based
upon power gas pressure and discharge gas pressure�
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 the 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 that
permits a balance between greater accuracy (from a smaller
deadband) and minimal bleed gas�

Becker HPP-5 High Pressure Positioner Maintenance and Operation Manual | 4© 2014 General Electric Company. All rights reserved.
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 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 that permits a balance between greater
accuracy (from a smaller deadband) and minimal bleed gas�
Your HPP-5 positioner will come factory adjusted for your
particular application� The use of the adjustment procedures will
be necessary upon installation of a rubber goods replacement kit
or any other disassembly or reassembly of the positioner�
Adjustment Procedure
The sensitivity adjustment drum on one end of the positioner
determines the sensitivity of the unit�
The variable orifices determine the stroking speed of the
positioner�
Initial Adjustment
1� Adjust the supply regulator:
Adjust the supply regulator to the desired power gas pressure�
Refer to the original invoice paperwork supplied with the product
for the appropriate power gas pressure setting� It is imperative
that adequate supply gas pressure be supplied to the regulator
pilot to help ensure proper operation of the system and all
accessories�
2� Adjust the adjustable orifices:
The adjustable orifices are used to control the volume of gas that
is supplied to the HPP-5 positioner� The stroking speed of the
system is proportional to the numerical value of the adjustable
orifice� Adjustable orifice settings are typically equal for both
orifices� However, a few applications may require unequal settings
for each adjustable orifice� Set both orifices according to the table
on page 5�
NOTE: To determine the cylinder bore, look at the model number
stamped on the stainless steel tag on the top of the cylinder� The
cylinder bore will be the second number in the alphanumeric
model code� This one or two digit number will be the diameter in
inches (for example, a unit with the model number 6H8F6FG-H4
has an 8-inch bore)�

5 | GE Oil & Gas © 2014 General Electric Company. All rights reserved.
Supply Pressure (psig) Cylinder Bore (in.)
4 5 6 8 10 12 14
Variable Orifice
Up to 50 3 3 3 4 4 5 6
51-200 2 2 3 3 4 5 6
201-600 2 2 2 3 3 4 5
Supply Pressure (psig) Cylinder Bore (in.)
4 5 6 8 10 12 14
Variable Orifice
Up to 50 3 3 3 4 4 5 6
51-200 4 4 4 5 4 6 6
201-600 2 2 2 3 3 4 5
Table A - Exhaust Vented to Atmosphere
Table B - Exhaust Vented to Pressure System
Deadband Setting
1� Turn the deadband adjustment drum in the direction of
increasing numbers until the drum can no longer turn�
Then turn the adjustment drum one full turn in the opposite
direction (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 adjustment screw in the
middle of its travel range�
4� Apply power gas to the HPP-5 positioner�
5� 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)� Allow the actuator to stroke the valve to an intermedi-
ate position and the gauge pressures to balance� (if the valve
does not stroke, ensure that the positioner is communicating
with the actuator cylinder)� If equipped with an MCV-3 manual
control valve, make sure the left handle is in automatic�
6� If the actuator is equipped with an MCV-3 manual control
valve), place the left handle in the manual position� If the
actuator is not equipped with an MCV-3 manual control valve,
use the block valve (1/4-inch ball valve) installed between the
positioner output and the actuator� Once the actuator has
reached its desired position (based on the mid-signal applied
to the instrument port – Step 5), place the block valve in the
closed position�
7� Final Sensitivity Drum Adjustment for positioner’s bleeding
to atmosphere: Disconnect any bug vent or tube fitting from
the exhaust port� Turn the deadband adjustment drum in
the direction of decreasing numbers, until the exhaust port
begins to bleed gas� Then turn the drum in the opposite
direction until the exhaust port stops bleeding�
The unit is properly adjusted if increasing or decreasing the
input signal by �2 psig causes the cylinder top and bottom
gauges to develop a differential equal to at least 20 percent
of power gas�
Replace the exhaust fitting�
For positioner’s bleeding to a pressure system:
Slowly decrease the setting of the deadband (decreasing
numbers) until both cylinder gauges are equal and read 90 to
95 percent of power gas pressure�
NOTE: When increasing or decreasing the instrument signal,
the output pressure should swing up and down� When
changing direction of the false instrument signal, the output
pressure 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� Place the instrument signal to automatic and open the block
valves or return the left handle of the MCV manual control
valve to automatic�

Becker HPP-5 High Pressure Positioner Maintenance and Operation Manual | 6© 2014 General Electric Company. All rights reserved.
Bias Adjustment
For Standard (Non-Split Range) Systems:
1� To increase the bias setting, increase tension on the range
spring� This is accomplished by either raising the spring
retainer or screwing the bias adjustment stud into the indica-
tor bar or tail rod� Note the two jam nuts tightened against
one another to adjust the length of the stud� When properly
adjusted, tighten the bias lock nut(s)�
2� To decrease the bias setting, decrease tension on the range
spring by either lowering the spring retainer or screwing the
bias adjustment stud out of the indicator bar or tail rod� Note
the two jam nuts tightened against one another to adjust the
length of the stud� When properly adjusted, tighten the bias
lock nut(s)�
For Split Range Systems (see Table 1)
3� Find the bias adjustment screw (1/2-20 thread with 3/8 flats)
on the end of the positioner opposite to the pneumatic signal
input 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�
Table 1. Adjustable Bias Springs
Table 2. Range Spring Configurations
Spring
(part number)
Range
(psig)
Green (20-2592) 1-6
Silver (25-1038) 2-11
Blue (25-1036) 4-20
Red (25-1037 8-30
Spring
Range (psi)
Stroke (Part Number)
4” 8” 12” 14”
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
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 instrument signal to the HPP-5 positioner starts
valve movement until the end of the valve stroke and full pressure
differential across the cylinder output gauges�
1� After setting the bias for the start of the valve travel,
continue increasing the instrument signal until the valve
stroke is completed and the cylinder output gauges show full
power gas pressure differential�
2� Be sure not to overshoot at this point as any signal level
above this upper limit will show the same reading on the
cylinder gauges� This point is the highest end of the range,
and the value may not necessarily be equal to the desired
upper range value�
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 counterclockwise 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 provides 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
nonstandard ranges (refer to Table 3)�
Table 3. Range Spring Retainer
Type (part number) Typical Use
Short (01-2509) 8” and 12” Stroke
Intermediate (11-
2572)
6” Stroke
Long (01-2042) 4” Stroke
Changing Positioner Action
To change the positioner from open on increasing signal to close
on increasing signal, or vice versa, the following parts kits must be
ordered:
To change open on increasing to close on increasing: Part
#25-1444 plus an extension rod� The serial number of the actuator
must be specified� The exact part number of the extension rod will
vary based on the actuator stroke�
To change close on increasing to open on increasing: Part #25-
1289� Note: If converting a close on increasing signal positioner
to open on increasing signal, the wide end of the tube may be
shortened by 11/16 of an inch with a hacksaw instead 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 from the
regulator model number� The stroke length is the second letter 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 in the Appendix for the following:
1� Disconnect all supply lines, instrument line, and output line
from the positioner�
2� Remove the range spring at both ends and those items
connecting it to the rod and the positioner feedback arm�

7 | GE Oil & Gas © 2014 General Electric Company. All rights reserved.
3� Remove the positioner from the bracket� 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 schematic provided by GE), then reattach to
the positioner� This will allow the positioner to maintain the
actuator failure mode when the positioner is turned upside
down�
4� Move the bracket assembly, tube assembly, and cover plate
to the positions shown on the desired drawing�
5� Install the positioner in the opposite direction 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 sur-
rounding hardware according to the drawing of the desired
configuration� (Note: All original parts may not be used when
converting from close on increasing to open on increasing�)
7� The entire bracket assembly or the outer angle may need
to be turned upside down to accommodate the new spring
height�
8� Reconnect the supply, instrument, and output 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)�
Table 4. Extension Rods for Positioners to Close on
Increasing Signal
Conversion to Split Range
Converting a standard positioner to a split range positioner (pneu-
matic 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 cartridge� 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 positioner 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 inside it�
2� Replace the cap and spring with the larger bias spring
cartridge and bias spring found in the kit� Make sure the bias
adjustment screw in the bias spring cartridge 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 cartridge�
Reattach the mounting bracket upside down from its original
position�
4� Slide the thread spacer (brass bushing) over the adjusting
screw and tighten the washer and jam nut against the thread
spacer�
5� If a range spring was sent with the kit, remove the existing
range spring and replace it with the new one�
6� Adjust the unit per the Adjustment Procedures�
Stroke With Transmitter Without Transmitter
4” 25-1402 25-8001
6” 25-8136 25-1093
8” 25-1402 25-1423
NOTE: Refer to Table 1 and Table 2 for bias and range spring part
numbers
Table 5. Split Range Conversion Kits
Maintenance and Inspection
As with all precision equipment, it is necessary to periodically test
the positioner to help ensure top performance� We recommend
the following procedure once a year�
1� Shut off supply pressure and bleed down at positioner� Note
the settings of the variable orifices and remove them from
the orifice assembly� Clean them thoroughly and reinstall
using new o-rings, while being sure to install each orifice in
the same hole from which it was removed (the orifice and
block have matching numbers for this purpose)� Reset orifices
to original settings� Turn on supply pressure�
2� Apply a midrange signal to the positioner� Allow the control
valve to become stationary at about 50 percent of the range�
Close the cylinder block valves or move the MCV-3 handle
to the manual position� The positioner is now isolated from
the cylinder� Apply a ± 1/4 psig signal change� Observe the
response in the output gauges� The output pressure should
develop differential pressure equal to 20 percent of the power
gas pressure� If the output pressure does not show immedi-
ate response, the positioner may have too much deadband�
Reduce the deadband by turning the drum in the direction
of decreasing numbers� If the pressures do not respond in
the correct direction when reversing the instrument signal
change, the unit has internal friction� Disassemble the unit
and replace all rubber goods�
3� Check the integrity of the balance valve seats by increasing
the deadband by one full number� When the cylinder top and
bottom gauges are equal to the power gas, the exhaust port
should not exhibit any bleed gas� If either of these tests fail,
then the positioner is not properly adjusted or the unit needs
to be reassembled with new rubber goods�
4� Soap test around all diaphragm interfaces, orifice
assemblies, and vents� If any leaks are found around the
diaphragms, refer to the assembly instructions for replace-
ment of all internal rubber parts�
5� Observe the operation of the gauges� If any gauges are
defective, replace them�
6� Check range and bias� If necessary, readjust per Adjustment
Procedures� Should problems arise or more information is
required, call toll free [phone] for assistance�
Stroke Close on
Increasing
Open on
Increasing
Reference
Drawings
4 inch 25-6014 25-1464 Proportional:
35-0513
35-0313/A
35-0511
35-0511/A
6 inch 25-6014 25-1465 Proportional:
35-0522
35-0529
8 inch 26-6014 25-1466 Tailrod:

Becker HPP-5 High Pressure Positioner Maintenance and Operation Manual | 8© 2014 General Electric Company. All rights reserved.
Model HPP-5 Single-Acting Positioner Annual Maintenance Checklist
1� ________ Soap test all diaphragm mating surfaces to check for leaks�
2� ________ Replace rubber goods using Becker Model HPP-5 Single-Acting Positioner Repair Kit (Part # 30-9601) if
necessary�
3� ________ Confirm power gas supply pressure is correct� Refer to original GE invoice paperwork for
proper power gas setting�
4� ________ Observe operation of gages and replace if defective�
5� ________ Check integrity of HPP-5 positioner seats� Varying input signal 1 psig should send one cylinder
output gauge to full power gas� Refer to Procedure 7, page 5�
6� ________ Check response of HPP-5 positioner� Varying input signal 1/4 psig should produce cylinder
output gauge differential equal to 40 percent of power gas� Refer to Procedures 6-8, page 5�
7� ________ Check range and bias of HPP-5 positioner and adjust if necessary� Refer to page 6�
8� ________ Inspect and verify proper operation of all HPP-5 positioner accessories� Refer to technical
manual included with each specific instrumentation accessory for further instruction�
NOTE: It is not necessary to replace any rubber goods in Becker instrumentation or instrumentation accessories on a regular basis�
However, common practice suggests that replacement of rubber goods on a five-year cycle basis provides adequate preventative
maintenance�
Parts Ordering
The following is provided to allow the ordering of replacement parts� Please specify the Becker instrument serial
number when ordering parts (this can be found on the stainless steel tab attached to the pilot by the 7/16 hex
head cap screws� If the instrument was supplied as a complete valve regulator package, the stainless tag attached
to the actuator piston also can provide the serial number�
Key Description Part No.
1 Pilot base 30-7005
2 Lexan Cover 25-1034
3 Adjusting Drum 35-1520
4 Washer 25-1016
5 Inside piston 35-1507
6 Orifice Assembly 35-1015
7 Seat Cover 35-1519
8 1/2-20 Jam Nut 98-3056
9 Beam Adjusting Drum 25-1124
10 Diaphragm 25-1213
13 1/8 Roll Pin SS 98-2950
14 8-32 x 1” SHCS 98-3144
15 Beam Block 25-1086
16 Outside piston 25-1018
17 3/16 x 1/2 Roll Pin SS 98-3089
18 1/4-20 x 2-1/2 HHCS 98-3180
19 Gauge Manifold 35-1013
20 O-Ring –012 95-2615
21 1/4-28 Jam Nut 98-3214
22 Diaphragm w/ Con-
volute
25-1027
23 Beam Spacer 30-7055
24 1/4-20 x 1” HHCS 98-2579
25 3-15 pressure car-
tridge
25-1082
Key Description Part No.
26 5-40 x 1/4 SHCS 98-2629
27 1/4-20 x 3/4 SHCS 98-3137
28 8-32 x 1/2 SHCS 98-2614
29 Pilot Post S�S� 35-1521
30 Double pilot Body 35-1504
31 Valve Adjusting Screw 35-1517
32 Balance valve as-
sembly
35-1510
33 Seat assembly 01-7082
34 S�S� Control tag 25-1061
35 10-32 x 3/8 FHMS 98-2684
36 #10 Lockwasher 98-3178
37 Strainer for Balance
valve
35-1559
38 Seat Spacer 35-1526
39 Beam 25-1084
Seal Kit
A seal kit containing diaphragms, o-rings, and seats, for the HPP-5
positioner is available directly from GE� Simply contact GE and
order part number 30-9601�

9 | GE Oil & Gas © 2014 General Electric Company. All rights reserved.
HPP-5 Positioner Parts List
(c)
(c) ALUM. NUT IN PLACE OF SS. NUT
3-15-04
DB
ECR02-04
8
30-0601
MODEL# HPP-5
HIGH PRESSURE POSITIONER
1-26-99
1:5/8
TS
DRAWING NUMBER
APPR0VED
BY:
B
DWG. SIZE
REVISED BY: TS
REVISED DATE: 5-3-04
DRAWN BY DATE:
SCALE:
11
5-14-99
S.S.=2
N/A TS (a) ALL REF TOL WLD. ARE DONE
DATE
BY REVISI0N
REP#
21
FIG.-1
28
14
29. 2 35-1521 PILOT POST
30. 1 35-1504 DOUBLE PILOT BODY
31. 1 35-1517 VALVE ADJ. SCREW
32. 2 35-1510 BALANCE VALVE ASSY.
33. 2 01-7082 SEAT ASSY.
34. 1 25-1061 SS CONTROL TAG
35. 2 98-2684 10-32 x 3/8 FHMS
36. 2 98-3178 #10 LOCKWASHER
37. 2 35-1559 STRAINER FOR B.V.
38. 2 35-1526 SEAT SPACER
39. 1 25-1084 BEAM
12
ITEM QTY. PART NO. DESCRIPTION
1. 1 30-7005 PILOT BASE
2. 1 25-1034 LEXAN COVER
3. 1 35-1520 ADJUSTING DRUM
4. 4 25-1016 WASHER
5. 1 30-7004 INSIDE PISTON
6. 1 35-1015 ORIFICE ASSY.
7. 1 35-1519 SEAT COVER
8. 1 98-3056 1/2-20 JAM NUT-SS
9. 1 25-1124 BEAM ADJUSTING DRUM
10. 1 25-1213 DIAPHRAGM
11. 6 95-2609 O-RING -010
12. 1 25-1065 1/2-20 SPECIAL NUT ALUM
13. 1 98-2950 1/8 ROLL PIN SS
14. 4 98-3144 8-32 x 1" SHCS
15. 1 25-1086 BEAM BLOCK
16. 1 35-1506 OUTSIDE PISTON
17. 4 98-3089 3/16 x 1/2 ROLL PIN SS
18. 4 98-3180 1/4-20 x 2 1/2 HHCS
19. 1 35-1013 GAUGE MANIFOLD
20. 6 95-2615 O-RING -012
21. 1 98-3214 1/4-28 JAM NUT
22. 2 25-1027 DIAPHRAGM W/CONVOL.
23. 1 30-7055 BEAM SPACER
24. 6 98-2579 1/4-20 x 1" HHCS
25. 1 25-1082 3-15 PRESSURE CARTRIDGE
26. 1 98-2629 5-40 x 1/4 SHCS
27. 12 98-3137 1/4-20 x 3/4 HHCS
28. 2 98-2614 8-32 x 1/2 SHCS
1) ITEMS NO
.8, 24, AND 27 ARE
TORQUED TO 95-100 in. lbs.
2) ALL FASTENERS ARE STAINLESS STEEL.
3) KIT#30-9601
4) JAM NUT (ITEM 21) SHOWN IN L
OCK
POSITION.
NOTES:
30
27
25 24
23
22
15
10
9
12
4 3 2 1
6" DIA. REF.
SIGNAL
26
435
0
2
4
6
0
2
4
6
56
7 16 17
18
1920
29
31
32
33
34
FIG.-1
35
36
37
7
38
14
13
39
(b) #11) 25-1123 & #12) 25-1217
WERE REMOVED (BOTTOM SPRING)
TS
N/A 7-7-99
BECKER Precision
Equipment
DRESSER INC.

Becker HPP-5 High Pressure Positioner Maintenance and Operation Manual | 10© 2014 General Electric Company. All rights reserved.
HPP-5 Positioner Appendix
SEE FIG.1
FIG. 2
FIG. 1
SEE FIG.2
5 3 4
SPRING
CARTRIDGE
25-1009
FOR HPP-SB
SPACER
(25-8145)
1/2-20 HEX
JAM NUT
(98-3056)
SPACER
(50-1283)
3/8 I.D.
LOCKWASHER
(98-2782)
3/8 FLAT
WASHER
(98-2780)
3/8-16 X 1 1/4 HHCS
(98-2583)
ADJUSTING SCREW
(25-1035)
(FOR SPLIT RANGE)
BIAS
SPRING
54
3
SPLIT RANGE CONVERSION
ASSEMBLY 30-0503
CYLINDER
12 3
4
5
67
8
9
10
11
12
13 14 15
16
17
18
19
NOTES:
1) REGULATOR TO OPEN ON INCREASING
SIGNAL
20
3) ASSY. IS SHOWN WITH REGULATOR IN
FULL CLOSED POSITION.
2) SEE DRAWING #30-1207 FOR
CL
OSE ON INCREASING SIGNAL.
21
ROD
CLEVIS
HOUSING
ASSY.
INSTRUMENT
GAUGE
HPP
09-13-93
NTS
TS
DRAWING NUMBER
APPR0VED
BY:B
DWG. SIZE
REVISED BY: DB
REVISED DATE: 2/12/04
DRAWN BY DATE:
SCALE:
30-1208
ITEM QTY. PART# DESCRIPTION
1. 1 95-2643 O-RING-24
2. 1 25-1095 SPRING RETAINER
3. 1 95-2644 O-RING-30
4. 1 25-1289 SHORT TUBING
5. 1 TUBE HOLDER
6. 1 25-1310 ACCESS COVER
7. 1 25-1131 BOTTOM COVER
8. 1 25-1230 8" STK. HPP-2 BOX
9. 1 98-2500 7/16-20 JAM NUT
10. 1 25-1141 STUD
11. 1 01-2509 RETAINING SCREW
ITEM QTY. PART# DESCRIPTION
12. 1 25-1334 8" STK. TOP BOX
13. 1 25-1149 RANGE SPRING LOCK
14. 1 98-3171 8-32 X 1/4 RHMS
15. 1
50-1230
RANGE SPRING
16. 1 FLANGE
17. 1 50-1220 8" STK. LEXAN COVER
18. 1 INDICATOR BAR
19. 1 25-1336 8" STK. GUIDE BAR
20. 1 25-1311 POS. MTG. BRACKET
21. 1 25-1412 LIMIT SWITCH COVER
BECKER Precision
Equipment
DRESSER INC.
HPP-OI-8-SR-SPL
8" STK. HPP ASSEMBLY
25-1133

11 | GE Oil & Gas © 2014 General Electric Company. All rights reserved.
SEE FIG.2
BIAS
SPRING
5
43
FIG. 1
FOR HPP-4 & HPP-5
SPLIT RANGE CONVERSION
ASSEMBLY 30-0503
FIG. 2
(FOR HPP-SB
ONLY)
BIAS
SPRING
1/2-20 HAX
JAM NUT
(98-3056)
SPRING
CARTRIDGE
(25-1048)
1/2" FLAT
WASHER SS
(98-3185)
THREAD
SEAL
(25-1203)
534
SEE FIG. 1
30-1207
HPP-CI-8-SR-SPL
8" STK. HPP ASSEMBLY
SCALE:
DATE:
DRAWN BY
REVISED DATE: 2/12/04
REVISED BY: DB
DWG. SIZE B
APPR0VED
BY:
DRAWING NUMBER
TS
NTS
06-12-94
20
19
18
17
16
15
21
14
R0D
CLEVIS
CYLINDER
H0USING
ASSY.
13
12
1110
9
8
7
65
43
2
1
4) SEE DRAWING #30-1206
FOR OPEN ON INCREASING
SIGNAL.
3) ASSY. IS SHOWN WITH
REGULATOR IN FULL
OPEN POSITION.
2) THE ORIFICE ASSEMBLY IS
CALIBRATED TO ASSURE
EQUAL RATE OF FLOW
FROM BOTH ORIFICES.
1) REGULATOR TO CLOSE
ON INCREASING SIGNAL
N0TES:
HPP
INSTRUMENT
GAUGE
BECKER Precision
Equipment
DRESSER INC.
ITEM QTY. PART# DESCRIPTION
1. 1 50-1230 FLANGE
2. 1 25-1310 ACESS COVER
3. 1 98-3171 8-32 X 1/4 RHMS
4. 1 25-1149 RANGE SPRING LOCK
5. 1RANGE SPRING
6. 1 95-2643 O-RING -024
7. 1 25-1134 LONG TUBING
8. 1 95-2644 O-RING -030
9. 1 01-2509 SPRING RETAINER SCREW
10. 1 25-1311 POSITIONER MTG. BRACKET
11. 1 25-1133 TUBE HOLDER
ITEM QTY. PART# DESCRIPTION
12. 1 25-1085 CONNECTION BEAM
13. 1 25-1131 BOTTOM COVER
14. 1 50-1220 8" STK. LEXAN COVER
15. 1
25-1335
INDICATOR BAR
16. 1 8" STK. EXTENTION ROD
17. 1 25-1230 8" STK. HPP-2 BOX
18. 1 25-1095 RANGE SPRING RETAINER
19. 1 25-1141 STUD
20. 1 25-1334 8" STK. TOP BOX
21. 1 25-1336 8" STK. GUIDE BAR
HPP-5 Positioner Appendix

Becker HPP-5 High Pressure Positioner Maintenance and Operation Manual | 12© 2014 General Electric Company. All rights reserved.
HPP-5 Assembly Procedure
Assembly
NOTE: During assembly, moisten O-rings, threads, thrust bearings,
and the spring seat recess with a lightweight silicone grease�
Step 1� Using a 7/16-inch deep well socket, insert bottom seat
(rubber facing upward) (E) into the pilot body block (F)�
1a� Install strainer for balanced valves (D1) in the outside of
spacer (D) and insert assembly on top of bottom seat (E)�
1b� Insert the balanced valve assembly (C) with the stem facing
downward�
1c� Insert the second balanced valve assembly (C) with the stem
facing upward�
1d� Insert the second strainer (D1) and spacer (D) assembly�
1e� Insert the top seat (rubber facing downward) (E)�
1f� Secure the seat assembly to the pilot body block (F) with
two washers (C1), seat cover (B), and two flat head machine
screws (A)�
NOTE: Install washers to compensate for tolerance variations�(For
steps 2-2a, refer to Figure 2)�
Step 2. Slide two -010 O-rings (G) onto valve adjusting
screw (H) and into the grooves at the top of the screw�
Do not lubricate the upper O-ring�
2a� Turn valve adjusting screw (H) into the inside piston (I) until
the screw head is flush with the piston recess�

13 | GE Oil & Gas © 2014 General Electric Company. All rights reserved.
Step 3� Place O-ring -011 (X1) in the adjusting orifice (W)� Place the
assembly in the gauge manifold (V) as shown�
3a� Place O-ring -011(X1) in the nuts (X) and secure the adjusting
orifice (W) with nuts (X) in the gauge manifold (V) as shown�
3b� Seat the four –012 O-rings (L) and roll pins (M) into
the inlet and exhaust port recesses on the pilot body block
(F)� (Note the orientation of the body in relation to the orifice
block)�
3c� Attach orifice block (K) and gauge manifold (N) to the pilot
body block (F) with four 1/4 - 20 x 2 1/2-inch stainless steel
hex head cap screws (J) by lining it up with roll pins (M) in pilot
body block (F)
Step 4. Test the pilot body block (F) for leakage� Using 1/4-inch NPT
plugs, plug the orifice block ports (K) and the gauge manifold (N)�
4a� Connect a pressure source to the orifice block (K) as shown�
Use approximately 100 psig for testing�
4b� With the pressure source activated, soap test around the
balanced valve assembly (C) on both the bottom and the top
of the pilot� Place a bubble on the exhaust port and check for
leakage�
4c� If any leakage is detected, repeat the assembly procedure
from Step 1� (vertical cross hole must be blocked with plastic
plugs in order to check exhaust port)�
4d� Remove all plugs from all blocks/manifolds [K and N]�

Becker HPP-5 High Pressure Positioner Maintenance and Operation Manual | 14© 2014 General Electric Company. All rights reserved.
Step 5. Fasten the two posts (V) to the inside Ppston (W) with two
8-32 x 1/2-inch socket head cap screws (X)�
5a� Insert the assembly into pilot body block (F)�
5b� Fasten the outside piston (I) to the inside piston/post
assembly with two 8-32 x 1-inch SHCS (T)�
Step 6. Slide -012 O-ring (CC) onto the outside piston (I) and into
the groove near its base�
6a� Install one washer (Z) onto the shaft of the outside piston (I)
with the grooves facing upward�
6b� Install the convoluted diaphragm (AA) onto the shaft of the
outside piston as shown�
6c� Install one washer (Z) onto the shaft of the outside piston with
the grooves facing downward�
6d� Tighten the assembly with 1/2-20 hex jam nut (YY) onto the
outside piston (I) to 95-100 in� lbs�
6e� To assemble the inside piston (W), repeat Steps 6-6d�

15 | GE Oil & Gas © 2014 General Electric Company. All rights reserved.
Step 7. Install the 1/4–28 jam nut (DD) and adjusting drum (EE) in
the valve adjusting screw (J)� Connect the adjusting screw (H) and
adjusting drum (P) with one 5-40 x 1/4 socket head cap screws (Q)�
Step 8� Bolt pilot base (FF) to the pilot body (F) using six 1/4-20 x
3/4 hex head cap screws (GG), and place the lexan cover (HH) to
the pilot base (FF).
NOTE: Place nut (DD) against the drum (EE)� This will allow free
rotation of the drum (EE) for adjustment�
Step 9: Bolt beam spacer (JJ) to the main body (C) with six 1/4-20 x
3/4-inch hex head cap screws (DD)� Align holes in the beam spacer
(JJ) and in the beam adjusting drum (KK) as shown
Step 10. Screw the beam drum (KK) on to the piston (F) until it
stops� Then turn the beam drum the opposite direction until the
slot in the beam drum aligns with that of the beam spacer�
Step 11. Place the beam (NN) inside the beam block (LL) in the
direction shown and then place the 1/8 roll pin (PP) inside the
beam block to secure the beam�
Step 12. Install the beam block (LL) to the beam spacer (JJ) with
two 8-32 x 1-inch socket head cap screws (MM)�
Step 13. Place diaphragm (QQ) in the direction shown on top of
the beam drum (MM)�
Step 14. Bolt pressure cartridge (RR) to beam spacer (JJ) with six
1/4 - 20 x 1-inch hex head cap screws SS)�

Becker HPP-5 High Pressure Positioner Maintenance and Operation Manual | 16© 2014 General Electric Company. All rights reserved.

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