Becker HPP-4 Manuale utente

Instruction Manual

for

the HPP-4

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-4series positioner

represents a breakthrough in valve con-

trol technology for the natural gas in-

dustry. Built to exacting specifications,

the easily maintained unit offers highly

accurate control with excellent control

characteristics in a broad range of oper-

ating environments. The HPP-4series

positioner is designed such that its

bleed gas can be routed to a lower

pressure downstream or fuel gas sys-

tem, eliminating bleed gas completely.

This means significant savings to your

company in terms of minimizing expen-

sive 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-4positioner is used in

control valve assemblies with a control-

ler or I/P transducer and double acting

actuator to provide accurate flow or

pressure control. The HPP-4 can be

used with various valve types that utilize

a double acting pneumatic piston ac-

tuator. The HPP-4 design positioner

represents Becker’s commitment to

continuos development of new products

and updating of existing products to

maximize their performance while re-

taining simple operation and minimum

maintenance.

Valves over 16” in diameter require the

use of Becker VB-250 Volume boost-

ers.

Scope of Manual

This manual provides information on in-

stallation, operation, adjustment, and

maintenance of the Becker HPP-4po-

sitioner. For information concerning ac-

tuators, 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 Preci-

sion 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: (800) 323-8844

Tel: (847) 437-5940

Fax: (847) 437-2549

e-mail: [email protected]

HPP-42September 1999

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 moni-

tor regulator*

•High Gain systems that require

fast stroking speed (power plants,

fertilizer plants)*

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. Volume Boosters are

typically required for Becker RPDA and

LPDA Series actuators size 12T or larger

(2200 in3)

Bleed to Pressure System: The HPP-4

Positioner is typically utilized for applica-

tions with a discharge pressures of 350

psig or less in order to ensure adequate

speed of operation. Bleed to pressure

system eliminates atmospheric emis-

sions by keeping discharge gas in the

piping system.

High Gain Systems: Power plant feeds

and other similar systems require fast

stroking speed in order to satisfy re-

quired “gain” of the system. The VB-250

Volume Boosters are applied based

upon actuator size and required stroking

speed.

CVE Globe Pattern Control Valves: The

Becker HPP series positioners are com-

patible with the Globe style control valve,

but require a minimum of 2” of actuator

stroke for proper feedback and opera-

tion. 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-4 with genuine Becker

control valve actuators. Should you al-

ready have existing control valve actuator

(s) in service, the addition of a Model

HPP-4 can improve performance and

eliminate atmospheric bleed emissions if

using the BPS (Bleed to a pressure sys-

tem) feature.

Some Compatible Actuators:

•Bettis T-Series Piston Actuators

•Fisher Type 470 Piston Actuators

•Fisher Type 1061 Piston

HPP-43September 1999

HPP-4 Positioner

Instruction Manual

Maximum Supply Regulator Capacity

Q = Min. Supply Regulators Capacity (scfh)

G= Specific Gravity of Gas

T= 460 + Operative Temperature (°F)

Cv = Flow Factor

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.

•PS 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.

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

Adjustable: 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: Reverse Acting: Open on loss of signal.

Direct Acting: Close on loss of signal.

Connections: All Ports: ¼” N.P.T.

Action: Direct and Reverse Acting:. Field-

reversible

Performance: Resolution: 0.2%

Hysteresis: 1.0%

Flow Capacity: CV= 1.5

Steady State

Consumption:

See Table in Appendix

Power Gas Require-

ment:

Use clean, dry filtered (100 micron)

gas.

Discharging to Atmosphere:

250 psig maximum.

Operative Temperature

Limits:

-20 to 160°F

(-28 to 70°C).

Housing: Meets NEMA 3 classification (weather

tight).

Installation Orienta-

tion:

Vertical or horizontal position allow-

able.

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-4 Positioner

Specifications

Technical Specifications Materials of Construction

HPP-44September 1999

Q = 312.86 x P1x CVx

)(

460

+× TG

Principles of Operation

Close on Increasing Signal

The positioner is a force-balanced instrument that provides a control valve posi-

tion 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 differen-

tial between the supply and discharge pressures. In steady state, the forces im-

posed on the balance beam by the input signal diaphragm and the range spring are

equal; therefore, the distance between the top and bottom seats and nozzles in the

positioner is equal. This causes the cylinder top and bottom pressures to be equal,

and the control valve is stationary. An increase in the input signal pressure results

in the lower seat being pushed into the lower nozzle due to an imbalance in the

beam forces. At the same time, the top seat moves away from the top nozzle.

This increases the pressure in the cylinder bottom, while the pressure in the cylin-

der top decreases. 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’s sensitivity adjustment effects

the responsiveness of the positioner nozzles. The greater the seat and nozzle sen-

sitivity, the greater the accuracy of the positioner.

HPP-45September 1999

Power Gas and Cylinder Bottom

Cylinder Top

Exhaust

Instrument Signal

HPP-4 Positioner

“How-It-Works”

Open on increasing Signal

The positioner is a force-balanced instrument that provides a control valve posi-

tion 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 distance between the top and bottom seats and nozzles in the posi-

tioner is equal. This causes the cylinder top and bottom pressures to be equal, and

the control valve is stationary. An increase in the input signal pressure results in the

upper seat being pushed into the upper nozzle due to an imbalance in the beam

forces. At the same time, the bottom seat moves away from the bottom nozzle.

This increases the pressure in the cylinder top, while the pressure in the cylinder bot-

tom decreases. The control valve begins to open. The actuator rod stretches the

range spring, increasing its tension. This force, which opposes the force on the bal-

anced 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 posi-

tion for the applied input signal. The positioner’s sensitivity adjustment effects the

responsiveness of the positioner nozzles. The greater the seat and nozzle sensitiv-

ity, the greater the accuracy of the positioner.

HPP-4 Positioner

“How-It-Works”

Power Gas and Cylinder Bottom

Cylinder Top

Exhaust

Instrument Signal

HPP-46September 1999

Your HPP-4 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.

HPP-47September 1999

SUPPLY

PRESSURE

(psig)

CYLINDER BORE (IN.)

456810 12 14

VARIABLE ORIFICE NUMBER

Up to 50 3334456

51-200 2233455

201-600 2223345

Important Note: For HPP-4 equipped with VB Series Volume Boosters, set variable orifices between 1 and 2

regardless of the cylinder size. Steady state gas consumption is minimized at 1. For additional information

on VB Series Volume Boosters refer to Accessories section of this manual.

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 de-

sired Power Gas pressure. Refer to the

original invoice paperwork supplied

with the product for the appropriate

Power Gas pressure setting. It is im-

perative that adequate supply gas pres-

sure be supplied to the VRP-CH in or-

der to ensure proper operation of the

system and all accessories.

2. Adjust the adjustable orifices:

The adjustable orifices are utilized to

control the volume of gas that is sup-

plied to the HPP-4.

The stroking speed of the system is

proportional to the numerical value of

the adjustable orifice. Adjustable ori-

fice settings are typically equal for both

orifices. However, a few applications

may require unequal settings for each

adjustable orifice. Refer to Fine Tuning

for more information on utilizing une-

qual adjustable orifice settings. Set

both orifices according to the table be-

low.

Notes:

•If the HPP-4 is NOT equipped with

VB Series Volume Boosters, set the

variable orifices to the recom-

mended value per the Table below.

If equipped with volume boosters,

see note below the table. To deter-

mine 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 first number following the first

capital letter “H”. This one or two

digit number following the first “H”

will be the diameter in inches and

will be followed by another letter

(For example, a unit with the model

number 6H8F6FG-H4 has an 8"

bore). If equipped with a PS sensor

HPP-4 Positioner

Adjustment Procedures

6. If the actuator is equipped with an

MCV-3 Manual Control Valve), place

the left MCV-3 handle in the manual

position. If the actuator is not

equipped with an MCV-3, use the

block valve (1/4 “ 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 in-

strument port –Step 5), place the

block valve in the closed position.

7. Final Sensitivity Drum Adjustment

Turn the Sensitivity Adjustment to set

the Cylinder Top and Cylinder Bottom

at the proper Cylinder Balance Pres-

sure (Pc) - See Equation 1 and 2 below.

Turn Sensitivity Adjustment to the right

(decreasing numbers on the scale) to

increase the Cylinder Top/Cylinder Bot-

tom Pressures. Turn Sensitivity Adjust-

ment to the left (increasing numbers on

the scale) to decrease the Cylinder Top/

Cylinder Bottom Pressures.

The correct Cylinder Balance Pressure

(Pc) is found using the Cylinder Balance

Pressure equations:

HPP-4 Discharge to PRESSURE SYS-

TEM (NO Volume Boosters)

Pc= Pd+ [0.4*(Ps-Pd)] (Equation 1a)

HPP-4 Discharge to Atmosphere (NO

Volume Boosters)

Pc= 0.4*Ps(Equation 1.b)

Deadband Setting

1. Turn the deadband adjustment drum

in the direction of decreasing the

numbers until the drum can no

longer turn. Then turn the adjust-

ment drum one full turn in the oppo-

site 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 re-

tainer.

3. If not already adjusted, set the bias

adjustment screw in the middle of

its travel range.

4. Apply power gas to the HPP-4 posi-

tioner

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 ac-

tuator to stroke the valve to an inter-

mediate position and the gauge

pressures to balance. (if the valve

does not stroke, insure that the po-

sitioner is communicating with the

actuator cylinder. If equipped with

an MCV-3, make sure the MCV-3

left handle is in automatic.

Signal Line from Control-

HPP-48September 1999

HPP-4 Positioner

Adjustment Procedures

HPP-4 Discharge to PRESSURE SYS-

TEM (EQUIPPED with Volume Boost-

ers)

Pc= Pd+ [0.2*(Ps-Pd)] (Equation 2.a)

HPP-4 Discharge to ATMOSPHERE

(EQUIPPED with Volume Boosters)

Pc= 0.20*Ps(Equation 2.b)

Variables:

Pc = Cylinder Balance Pressure (psig)

Pd = Discharge Pressure (psig)

Ps = Power Gas (Supply) Pressure

Note: When increasing or decreasing

the instrument signal, the output pres-

sure should swing up and down. When

changing direction of the false instru-

ment 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 auto-

matic and open the block valves or

return the left handle of the MCV to

automatic.

HPP-4 Positioner

Bias Adjustment

For Standard (Non-split range) Sys-

tems:

1. To increase the bias setting, in-

crease tension on the range spring.

This is accomplished by either rais-

ing the spring retainer or screwing

the bias adjustment stud into the in-

dicator bar or tail rod. Note the two

jam nuts tightened against one an-

other to adjust the length of the

stud. When properly adjusted,

tighten the bias lock nut(s).

2. In order to decrease the bias set-

ting, decrease tension on the range

spring by either lowering the spring

retainer or screwing the bias adjust-

ment stud out of the indicator bar or

tail rod. Note the two jam nuts tight-

ened against one another to adjust

the length of the stud. When prop-

erly 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 the pneu-

matic 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.

Span Adjustment

Spring Lock

Balanced Beam

Proportional Topworks

Bias Lock Nuts (Qty. 2)

Spring Retainer

Bias Adjustment

HPP-49September 1999

HPP-410 September 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

HPP-4 Positioner

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 be-

tween 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-4starts 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 in-

strument signal until the

valve strokes 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 read-

ing 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.

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

Indice

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