Becker* FEP-1000/1500-CH Series Flexible Element Pilot

Transcription

1 GE Oil & Gas Becker* FEP-1000/1500-CH Series Flexible Element Pilot Instruction Manual GE Data Classification : Public

2 THESE INSTRUCTIONS PROVIDE THE CUSTOMER/OPERATOR WITH IMPORTANT PROJECT-SPECIFIC REFERENCE INFORMATION IN ADDITION TO THE CUSTOMER/OPERATOR S NORMAL OPERATION AND MAINTENANCE PROCEDURES. SINCE OPERATION AND MAINTENANCE PHILOSOPHIES VARY, GE (GENERAL ELECTRIC COMPANY AND ITS SUBSIDIARIES AND AFFILIATES) DOES NOT ATTEMPT TO DICTATE SPECIFIC PROCEDURES, BUT TO PROVIDE BASIC LIMITATIONS AND REQUIREMENTS CREATED BY THE TYPE OF EQUIPMENT PROVIDED. THESE INSTRUCTIONS ASSUME THAT OPERATORS ALREADY HAVE A GENERAL UNDERSTANDING OF THE REQUIREMENTS FOR SAFE OPERATION OF MECHANICAL AND ELECTRICAL EQUIPMENT IN POTENTIALLY HAZARDOUS ENVIRONMENTS. THEREFORE, THESE INSTRUCTIONS SHOULD BE INTERPRETED AND APPLIED IN CONJUNCTION WITH THE SAFETY RULES AND REGULATIONS APPLICABLE AT THE SITE AND THE PARTICULAR REQUIREMENTS FOR OPERATION OF OTHER EQUIPMENT AT THE SITE. THESE INSTRUCTIONS DO NOT PURPORT TO COVER ALL DETAILS OR VARIATIONS IN EQUIPMENT NOR TO PROVIDE FOR EVERY POSSIBLE CONTINGENCY TO BE MET IN CONNECTION WITH INSTALLATION, OPERATION OR MAINTENANCE. SHOULD FURTHER INFORMATION BE DESIRED OR SHOULD PARTICULAR PROBLEMS ARISE WHICH ARE NOT COVERED SUFFICIENTLY FOR THE CUSTOMER/OPERATOR S PURPOSES THE MATTER SHOULD BE REFERRED TO GE. THE RIGHTS, OBLIGATIONS AND LIABILITIES OF GE AND THE CUSTOMER/OPERATOR ARE STRICTLY LIMITED TO THOSE EXPRESSLY PROVIDED IN THE CONTRACT RELATING TO THE SUPPLY OF THE EQUIPMENT. NO ADDITIONAL REPRESENTATIONS OR WARRANTIES BY GE REGARDING THE EQUIPMENT OR ITS USE ARE GIVEN OR IMPLIED BY THE ISSUE OF THESE INSTRUCTIONS. THESE INSTRUCTIONS ARE FURNISHED TO THE CUSTOMER/OPERATOR SOLELY TO ASSIST IN THE INSTALLATION, TESTING, OPERATION, AND/OR MAINTENANCE OF THE EQUIPMENT DESCRIBED. THIS DOCUMENT SHALL NOT BE REPRODUCED IN WHOLE OR IN PART WITHOUT THE WRITTEN APPROVAL OF GE. ii GE Oil & Gas 2016 General Electric Company. All rights reserved.

3 Table of Contents Page Introduction...1 Description...1 Scope of Manual...1 Model Number Explanation...1 Technical Assistance...1 Technical Information...2 Advantages of the Combination Chamber FEP-CH Pilot...2 Technical Specifications...2 Materials of Construction...2 Applications...2 Ordering Information...3 FEP-CH Stock Numbers and Spring Ranges...3 Accessories...4 FSP Series Setpoint Change Pump...4 RSM Series Remote Setpoint Module...4 REM Remote Setpoint Module...4 Setpoint Change Indicator...4 NBV Series No Bleed Valve...4 Principles of Operation...5 Pressure Reducing Regulator Mode...5 Backpressure Regulator Mode...5 Explanation of Droop...7 Piping Schematics Downstream Pressure Control...9 Backpressure Control Drawings FEP-1000/1500-CH Pilot Spring Chamber FEP-1000/1500-CH Sensing Chamber FEP-1000/1500-CH Body FEP-1000/1500-CH Bottom Cartridge Assembly Procedures List of Recommended Tools...20 Parts Silhouettes...20 Introduction GE s Becker FEP-CH series single-acting pilot represents a breakthrough in valve control technology for the natural gas industry. Built to exacting specifications, this easily maintained unit offers highly accurate control characteristics over a wide range of operating environments. Description The Becker FEP-CH single-acting pilot provides pressure control when used with a boot or diaphragm style regulator. The FEP-CH measures downstream sensing pressure and positions the control element of the regulator to maintain the desired downstream pressure. The FEP-1000/1500-CH pilot may be used for pressure control applications with setpoints ranging from 550 psig to 1500 psig. The FEP-CH design pilot represents GE s commitment to continually develop new products and update existing ones to increase their performance while retaining simple operation and low maintenance. Scope of Manual This manual provides information on the installation, operation, adjustment, and maintenance of the Becker FEP-1000/1500-CH single acting pilot. For information concerning valves and accessories, refer to the instruction manuals provided with the specific product. Model Number Explanation The FEP-CH pilot is available in two different models to cover sensing pressures from 550 psig to 1500 psig. The number expressed in the FEP model designation is the maximum sensing pressure; for example, a FEP-1500-CH has a maximum sensing pressure of 1500 psig. To find your FEP model number, refer to the stainless steel tag attached to your pilot by the 7/16 hex head cap screws. 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 GE sales representative, sales office, or manufacturer before proceeding. Technical Assistance Should you have any questions, please contact your local GE sales representative or technical assistance at: GE Oil & Gas Attn: Becker Control Valves Technical Assistance Normandy Boulevard Jacksonville, FL USA Tel VALVE-GE General Electric Company. All rights reserved. Becker FEP-1000/1500-CH Series Pilot Instruction Manual 1

4 Technical Information Advantages of the Combination Chamber FEP-CH Pilot 1. Control spring surrounded by the natural gas media is protected against corrosion caused by exposure to the outside weatherconditions and condensation (specifically critical for vault installation). 2. The Sensing Pressure and the Control Spring forces in the FEP-CH are combined in the same CH combined chamber so that only the small net force is transmitted to the FEP-CH Pilot Body. In all other brands, the forces have a sandwich effect over the pilot body and the resulting force is crushing pilots. This feature contributes for a much higher sensitivity and smaller Lock-Up. See figure 1 below. 3. Larger measured variable chamber volume dampens control pressure signal, helping to compensate for vibration induced by poor location of sensing tap in area of flow pulsation and turbulence. 4. Control springs can be replaced without disturbing any diaphragms. 5. Springs are guided by the outside resulting in better alignment and higher sensitivity. 6. Totally friction free design. Other Brands Becker FEP-CH Supply Gas Maximum Flow Capacity Maximum Supply Pressure Inlet Maximum ΔP Maximum Sensing Pressure Maximum Discharge Pressure Outlet Maximum Bottom Chamber (for remote loading) Operative Ambient Temperature Range Approximate Weight Setpoint Range Installation Orientation External Parts Internal Parts Springs Diaphragm Seats and O-Rings Applications Table 1. Technical Specifications Table 2. Materials of Construction Anodized 2024 Aluminum/316 SS Available 316 Stainless Steel and 2024 Anodized Aluminum Alloy Steel Buna-N with nylon reinforcement Buna-N Primary Pressure Control Dry, Filtered (100 micron gas) See Cv Tables 1480 psig (10204 kpa) 1000 psig (6895 kpa) 1500 psig (10342 kpa) 1300 psig (8963 kpa) 1500 psig (10342 kpa) -20 to 160 F -29 to 71 C 6 pounds (2.7 kg) 550 psig psig (3792 kpa kpa) Overpressure Protection (Monitor) Vertical position recommended Underpressure Protection (Standby) Relief Valve Backpressure Control Power Plant Type Applications Figure 1. Schematic for the net force Compatible Regulators Redq Flexflo* American Meters Axialflow Fisher 399 Mooney Flowgrid* 2 GE Oil & Gas 2016 General Electric Company. All rights reserved.

5 Ordering Information When ordering parts for the FEP-1000/1500-CH there is important information that needs to be specified. Using Table 3 the correct spring number and color is chosen for your specific control range. Tables 4, 5, and 6, give correct nozzle size, variable orifice, and repair kit ordering information for your application. In all, when ordering the customer should follow this format: Ordering Example: BPE Model FEP-1000-CH-NC ( ), Pressure Control Range psig (Yellow Spring, ), 1/8 Nozzle ( ), M Orifice Assembly ( ) Table 3. FEP-1000/1500-CH Control Spring and Setpoint Information FEP-CH Model No. Control Range (psig/kpa) Spring Color (Part Number) Setpoint Change per Revolution of Setpoint Screw (psig/kpa) Setpoint Range Discrete Remote Control (SM-1100) Setpoint Range Analog (4-20 ma) Remote Control (SM-1000) FEP-1000-CH FEP-1000-CH-NC (1) psig kpa Yellow ( ) 143 psig 990 kpa 700 psig 4826 kpa 700 psig 4826 kpa FEP-1500-CH FEP-1500-CH-NC (1) psig kpa psig kpa Grey ( ) Violet ( ) 227 psig 1565 kpa 276 psig 1903 kpa 850 psig 5860 kpa 950 psig 6550 kpa 850 psig 5860 kpa 950 psig 6550 kpa (1) NC = Normally Closed, for backpressure control. Table 4. FEP-1000/1500-CH Nozzle Information Diameter Part No. Application 3/ Gas 1/ Liquid Table 5. FEP-1000/1500-CH Orifice Part Information Identification Stamp Standard (no stamp) Variable Orifice Assembly Orifice Only Part Number ( ) ( ) M ( ) ( ) L ( ) ( ) Table 6. FEP-1000/1500-CH Repair Kit Part Information FEP-CH Model Number Repair Kit Part # FEP-1000-CH FEP-1500-CH FEP-1000-CH-NC FEP-1500-CH-NC General Electric Company. All rights reserved. Becker FEP-1000/1500-CH Series Pilot Instruction Manual 3

6 Accessories The following accessories are available to enhance the operation or provide additional features to your FEP-CH series single-acting pilot control system. For additional information regarding a specific accessory, contact GE. FSP Series Setpoint Change Pump: Provides a simple and accurate method of applying false signal pressure during initial adjustment of the FEP pilot. The pump can provide a false signal pressure of 10%-20% in excess of working pipeline pressure which eliminates the need for nitrogen bottles or electronic calibration devices. RSM Series Remote Setpoint Module: The Remote Setpoint Module provides remote adjustment of FEP-CH Pilot setpoint via an electrical input signal. All Remote Setpoint Motors are equipped with internal limit switches to prevent over-travel of setpoint ma feedback of Remote Setpoint Module is standard. All Becker RSM Series remote Setpoint Modules are rated Explosion Proof Class1, Div 1 for use in hazardous locations. Standard RSM input signals are: Digital Input: 24 VDC and 120 VAC Analog Input: 4-20 ma command signal/24 VDC supply power and 4-20 ma command signal/120 VAC supply power REM Series Remote Setpoint Module: The REM model requires additional diaphragm and spacer. It can be used as pneumatic remote set point or differential controller. Input Pressure Here Setpoint Change Indicator: Provides a visual indication of the setpoint change from a known reference setpoint. This device reduces the time required to vary setpoint occasionally such as winter and summer setpoints for high and low pipeline system demand. Pneumatic Remote Loading: Provides ability to change setpoint by remote pneumatic pressure. Also, can be used to control differential pressure. 4 GE Oil & Gas 2016 General Electric Company. All rights reserved.

7 Principles of Operation Pressure Reducing Regulator Mode (Figure 2): In order to understand how the FEP-1000/1500-CH pilot works, refer to the diagram on page 6: when the outlet line pressure is above the set pressure of the pilot, the net force on the sensing diaphragm (represented by the down arrow in the spring chamber) is down. This brings the seat to the nozzle, and the pilot remains closed. The closed pilot seals the Flexflo jacket from the downstream line, allowing the jacket pressure to equalize with the inlet pressure. This balanced force closes the Flexflo. When outlet line pressure falls below the set pressure of the pilot, the spring force takes over and the net force on the sensing diaphragm is now up (represented by the up arrow in the spring chamber). This force moves the seat away from the nozzle and the pilot opens, allowing gas in the jacket to flow out to the downstream line. When pressure outside the regulator jacket drops, the flow through the Flexflo increases. In time, this increased flow raises the downstream pressure enough as to create a downward net force on the sensing diaphragm. Eventually, the downward force on the sensing diaphragm begins to close the nozzle and pressure builds again outside the Flexflo jacket. This pressure now restricts the flow through the Flexflo and the downstream pressure begins to decrease. When the downstream pressure decreases enough to equal the set pressure of the pilot, the pilot remains at an equilibrium condition and the jacket and inlet pressures are equal. Backpressure Regulator Mode (Figure 3): In this mode, the main block of the pilot is flipped upside-down, such that the nozzle faces down (refer to Figure 3). When the inlet line pressure is below the set pressure of the pilot, the net force on the sensing diaphragm (represented by the up arrow in the spring chamber) is up. This brings the seat to the nozzle, and the pilot remains closed. The closed pilot seals the Flexflo jacket from the downstream line allowing the jacket pressure to equalize with the inlet pressure. This balanced force closes the Flexflo. When inlet line pressure rises above the set pressure of the pilot, the net force on the sensing diaphragm is now down (represented by the down arrow in the spring chamber). This force moves the seat away from the nozzle and the pilot opens, allowing gas in the jacket to flow out to the downstream line. When pressure outside the regulator jacket drops, the flow through the Flexflo increases. In time, this increased flow lowers the upstream pressure enough to let the spring force create an upward net force on the sensing diaphragm. Eventually, the upward force on the sensing diaphragm begins to close the nozzle and pressure builds again outside the Flexflo jacket. This pressure now restricts the flow through the Flexflo and the upstream pressure begins to increase. When the upstream pressure increases enough to equal the set pressure of the pilot, the pilot remains at an equilibrium condition and the jacket and inlet pressures are equal. IN OUT NOZZLE MOLDED SEAT Figure 3. Block turned upside down for back pressure applications General Electric Company. All rights reserved. Becker FEP-1000/1500-CH Series Pilot Instruction Manual 5

8 Figure 2. FEP-1000-CH Principles of Operation Pressure Reducing Regulator Mode. 6 GE Oil & Gas 2016 General Electric Company. All rights reserved.

9 Explanation of Droop: Lock-up or droop depends on the amount of gas flowing through the supply orifice. The internal nozzle has to be large enough to unload the supply orifice. In steady-state the supply flow will be equal to the discharge flow. In order to understand Tables 7, 8, 9, 10 and 11, a sample derivation and calculation is given below: Given: P 1 = pressure at inlet, P 2 = pressure at outlet, A N = area of the nozzle, K = spring constant, D N = diameter of the nozzle, A D = area of the diaphragm A simple force balance equation in steady state shows: SPRING DIAPHRAGM F S = SPRING FORCE F D = DIAPHRAGM FORCE (1) F D = F S + F N The force from the nozzle (FN), is simply the difference in the pressure from the inlet and outlet multiplied by the area of the nozzle: (2) F N = (P 1 - P 2 ) x A N = ΔP x A N The force on the spring comes from the equation: (3) F S = K x X We can look at the case when the pilot is in steady-state and the nozzle and orifice are wide open. The maximum distance that this is achieved is when the seat is D N /4 inches from the nozzle opening. Therefore we know the maximum deflection of the spring is: (4) X = D N /4 Since we know the given spring constant, K, for a yellow or gray spring: (5) F S = K x (D N /4) F N = NOZZLE FORCE We are interested in the pressure droop, but (1) only solves for the total droop force. So now we introduce equation (6) in order to find the pressure droop (PD): (6) F D = P D x A D So now our final equation for the maximum droop will be: (7) P DMAX = (ΔP x A N + K x X)/ A D An important fact to note is that (4) happens only at the extreme case that the nozzle is wide open, when the full lift force is acting on the seat. Of course the pilot can also be in steady-state when the seat is at an intermediate position from the nozzle (not fully closed, but not quite at X = D N /4 either). Therefore we must multiply the ratio of the orifice and nozzle flow factors (C V ) by the full lift distance (D N /4) in order to find the correct spring deflection, X for different intermediate seat positions. (8) X (FOR INTERMEDIATE POSITIONS) = (C V ORIFICE /C V NOZZLE ) x (D N /4) 2016 General Electric Company. All rights reserved. Becker FEP-1000/1500-CH Series Pilot Instruction Manual 7

10 Note: As you follow the calculations take note of the highlighted boxes shown in Tables 7, 8, 9, 10 and 11. The boxes illustrate the values used in this sample calculation. Table 7. Nozzle Diameter, Flow Factor (C v ), Nozzle Area, Diaphragm Area Nozzle Diameter (in) C v A N (in 2 ) A D (in 2 ) 3/ / Table 8. Control Spring Constants Spring Type K (lbf/in) Yellow 2398 Grey 3794 Table 9. Orifice Flow Factor vs. Oricfice Opening #0-7 Orifice STD M L Flow Direct Opening Number Forward Reverse Forward Reverse Forward Reverse Sample Calculation For Droop: Given: A FEP-1000-CH gas application using a standard orifice set on #3 in the forward flow direction configuration. Find: The pressure droop for a ΔP of 800 psig. Solution: Because it is a gas application a 3/32 in. nozzle is used. From Table 7, the C V of this nozzle is and the nozzle area is in 2. Using the knowledge that the model is a FEP-1000-CH tells us that it uses a yellow spring. From Table 8 the spring constant of the yellow spring is 2398 lbf/in. From Table 9, the C V for a standard orifice set on #3 in the forward flow direction is Finally, the effective diaphragm area of the FEP 1000/1500 CH pilots is given from Table 7 as in 2. Using the tables we have found all the unknowns needed to solve for pressure droop, equation (7): ΔP = 800 psig A N = in 2 K = 2398 lbf/in X = (0.026/0.404) x ( /4) = in. A D = in 2 Table 10. Results For Sample Pressure Droop Calculations (Psig) (1) Nozzle Diameter (in) 3/32 1/8 Spring Color ΔP (psig) Yellow Grey Yellow Grey Table 11. Results For Sample Pressure Droop Calculations (Bar) (1) Nozzle Diameter (in) 3/32 1/8 Spring Color ΔP (psig) Yellow Grey Yellow Grey GE Oil & Gas 2016 General Electric Company. All rights reserved.

11 Table 10 shows the results of the droop calculation (equation 7) for ΔP values of 200, 400, 600, 800, and 1000 psig. For convenience, Table 11 shows the same results as Table 10 given in units of bars. From this we can see that for ΔP = 800 psig (55.2 bars) the pressure droop we can expect is 10.9 psig (0.8 bars). What Does It Mean? Droop is important to know about because it represents the increase in output pressure (P2) when the output is suddenly closed. Using the model FEP-1000-CH in a gas application with a ΔP = 800 psig as an example, we can see from Table 10 that if the output is suddenly closed the pressure will increase 10.9 psig (0.8 bars). (1) MAKE CAREFUL NOTE THAT TABLES 10 AND 11 ARE DONE FOR A SPECIFIC ORIFICE SETTING (#3). THESE TABLES ARE NOT VALID IF THE ORIFICE YOU USE IS DIFFERENT. IN OTHER WORDS, IF IN TABLE 9 YOU PICKED A #5 ORIFICE, ALL NEW CALCUATIONS WOULD APPEAR IN TABLES 10 AND 11. Piping Schematics Application #1 Downstream Pressure Control FEP-1000/1500-CH NORMALLY OPEN NOTE: REFER TO C V DATA FOR FORWARD AND REVERSE INSTALLATION IN THE TECHNICAL DATA SECTION Flexible Element Regulator (Grove Flexflo 900TE shown) DOWNSTREAM SENSING LINE (1000 PSIG MAX FOR FEP-1000-CH, 1500 PSIG MAX FOR FEP-1500-CH) 2016 General Electric Company. All rights reserved. Becker FEP-1000/1500-CH Series Pilot Instruction Manual 9

12 Piping Schematics Application #2 Backpressure Control FEP-1000/1500-CH NORMALLY CLOSED UPSTREAM SENSING LINE (1000 PSIG MAX FOR FEP-1000-CH, 1500 PSIG MAX FOR FEP-1500-CH) Flexible Element Regulator (Grove Flexflo 900TE shown) 10 GE Oil & Gas 2016 General Electric Company. All rights reserved.

13 FEP-1000/1500-CH Pilot Spring Chamber Assembly A, 7B 8A, 8B 9A, 9B Key Part No. Description Adjusting Screw /16-20 Jam Nut Seal Neck O-Ring O-Ring O-Ring A Std. Tube Cap 7B Tube Cap Gray Spring 8A Yellow Spring 8B Gray Spring 9A Standard Bearing Case 9B Gray Spring Bearing Case Thrust Bearing Bearing Nut /2-20 LH Jam Nut (316) Inner Tube /4-20 x 3 SHCS (316 SS) /16 FT Washer (SS) /16 Thread Seal /4-20 x 3/4 HHCS (SS) x 1/2 SHCS (Alloy) High Pressure Spring Cartridge x.500 Washer (Fiberglass) /4-20 x 1-1/2 SHCS (316 SS) FEP-1000/1500-CH Sensing Chamber Assembly Key Part No. Description Adapter Block O-Ring /2-20 Jam Nut (316) Thread Extension Small Washer O-Ring Top Spacer Conv. Diaphragm w/ Hole Small Piston 2016 General Electric Company. All rights reserved. Becker FEP-1000/1500-CH Series Pilot Instruction Manual 11

14 FEP-1000/1500-CH Body Assembly A, 41B Key Part No. Description Body Spacer Conv. Diaphragm W/Hole Piston w/seat O-Ring x 1/2 SHCS (Alloy) Piston Spacer /2-20 Jam Nut (316) /2-20 Special Nut /4-20 x 3/4 SHCS (Alloy) Single Body 41A /32 Nozzle 41B /8 Nozzle Pilot Post Small Washer FEP-1000/1500-CH Bottom Cartridge Assembly Key Part No. Description /4-20 x 3/4 HHCS (SS) Modified Bottom Cartridge 12 GE Oil & Gas 2016 General Electric Company. All rights reserved.

15 Assembly Procedures The following pages outline the complete assembly procedure for the FEP-1000/1500-CH. The complete assembly of the entire pilot is shown step by step. These procedures are given as a guide but it should be noted that only those qualified through training or experience should install, operate, or maintain the FEP pilot. If there are any questions concerning these instructions, please contact your GE sales representative, sales office, or manufacturer before proceeding. Note: During assembly moisten all O-rings, threads, thrust bearings and the recess in the spring seat with a lightweight silicone grease. HOWEVER, care should be taken to avoid applying grease to diaphragm sealing surfaces, as this may compromise diaphragm sealing. Single Body Assembly Step 1. Insert a 010 O-ring (A) into the groove of the 3/32 nozzle (B). Thread the nozzle (1) into the single body (C). (1) 3/32 nozzles are for gas applications. For liquid operation, use 1/8 nozzle instead. B A C P1 C P2 E D Piston Assembly Single Body Assembly Step 1. Insert 012 O-ring (D) into the grooves of each piston (E). Step 2. Attach two pilot posts (F) to one of the pistons using 2, 8-32 x 1/2 SHCS (G). Step 3. Slide the assembly from step 2 through the single body (C) and attach it to the other piston using 2 more 8-32 x 1/2 SHCS (G). Body Spacer Assembly Complete Piston Assembly Step 1. Insert a 145 O-ring (H) into each groove of the single body (C). G G D H E F P1 P2 C Pilot Post - Piston Assembly H Single Body O-Ring Assembly 2016 General Electric Company. All rights reserved. Becker FEP-1000/1500-CH Series Pilot Instruction Manual 13

16 Step 2. Slide a piston spacer (I) over each piston. The grooved side of the piston spacer should be facing away from the pistons as shown in Body Spacer Assembly Figure here below. Step 3. Fasten each body spacer (J) to the single body using 6, 1/4-20 x 3/4 SHCS (K). Take careful note of the orientation of the body spacers before fastening them to the single body. (C) Body Diaphragm Assembly Step 1. Slide a diaphragm (L) over each piston taking into account the diaphragm convolute orientation shown in Body Diaphragm Assembly Figure here below. Step 2. Slide a grooved small washer (M) over each piston taking into account the direction of the washer grooves shown in Body Diaphragm Assembly Figure here below. Step 3. Finish by threading a 1/2-20 aluminum nut (N) onto the top piston, and a 1/2-20 SS jam nut (O) onto the bottom piston. Torque both nuts to in.-lbs. K N (1/2-20 Aluminum) Body Spacer (J) Side View Small Washer (M) Side View Grooves Face Down P1 Piston Spacer (I) Side View Grooves Face Up C Diaphragm (L) Side View Convolute Up P2 Piston Spacer (I) Side View Grooves Face Down Diaphragm (L) Side View Convolute Down K Body Spacer (J) Side View O (1/2-20 SS) Small Washer (M) Side View Grooves Face Up Body Spacer Assembly Body Diaphragm Assembly 14 GE Oil & Gas 2016 General Electric Company. All rights reserved.

17 Centering the Diaphragms Step 1. Rotate the diaphragm assembly counter-clockwise until it stops. Mark the diaphragm and body spacer with a single line. Step 2. Rotate the diaphragm assembly clockwise until it stops. Mark the body spacer with an extension from the line already on the diaphragm. Step 3. Draw a line exactly between the two lines already on the body spacer. Center the diaphragm by rotating the diaphragm assembly counter-clockwise until the line that exists on the diaphragm matches the new center line on the body spacer. Bottom Cap Assembly Step 1. Turn the entire assembly upside down. Step 2. Fasten the bottom cartridge (P) to the bottom body spacer using 6, 1/4-20 x 3/4 HHCS (Q). Torque to in.-lbs. Q Step 1 P1 P P2 P2 Step 2 P1 P1 P2 Bottom Cartridge Assembly P1 Step 3 P2 Diaphragm Centering 2016 General Electric Company. All rights reserved. Becker FEP-1000/1500-CH Series Pilot Instruction Manual 15

18 CH Chamber Assemblies Assembling the Diaphragm 1000/1500-CH Diaphragm Assembly Slide 012 O-ring (A) onto the small piston (B). Place the diaphragm with hole (C) onto the piston (B). Slide the small washer (D) onto the piston (B). Attach the thread extension (E) onto the small piston (B). Torque to in.-lbs. Connecting the Two Pistons 1000/1500-CH Bottom Spacer Assembly Orient the bottom spacer (K) onto the top body assembly (L). Place the adapter block assembly onto the bottom spacer (K). Making sure not to twist the diaphragm (C), thread the small piston (B) into the outside piston (M) by holding the spring chamber (H) and rotating the inner tube (I) clockwise. The inner tube (I) is rotated with the same socket wrench used to hold the jam nut (J) in the adapter block assembly. When the inner tube (I) cannot be rotated any more, do not force it; this assembly should only be hand-tight. Assembling the Diaphragm 1000/1500-CH Adapter Block Assembly Insert 145 O-ring (F) into the adapter block (G). Place the adapter block (G) between the diaphragm assembly and spring chamber (H). Slide the inner tube (I) through the spring chamber (H). Attach the thread extension (E) to the inner tube (I) using 1/2-20 SS jam nut (J). Torque the jam nut (J) to in.-lbs. 16 GE Oil & Gas 2016 General Electric Company. All rights reserved.

19 Bolting the Spring Chamber 1000/1500 Spring Chamber Assembly Fasten the bottom spacer assembly to the top body assembly (L) using six (6) fiberglass washers (N) and six (6) 1/4-20 x 3-inch SHCS (O). Bolt the spring chamber (H) into the bottom spacer (K) using six (6) fiberglass washers (N) and six (6) 1/4-20 x 1 1 / 2 -inch SHCS (P) General Electric Company. All rights reserved. Becker FEP-1000/1500-CH Series Pilot Instruction Manual 17

20 Adjusting Screw Assembly Step 1. Press fit the thrust bearing (AA) into the bearing case (BB for a FEP-1000-CH and CC for a FEP-1500-CH). BB CC Step 4. Place the tube cap (HH or II) and control spring (JJ) onto the adjusting screw. Check the concentricity of the spring by spinning the assembly. Make sure that the spring touches no parts of the adjusting screw when spinning. If the spring does touch any part of the screw, then replace the spring and repeat the test. When spring satisfies this test, continue to the next step. HH or II AA JJ Press Fit Thrust Bearing and Bearing Case Step 2. Slide a 108 O-ring (DD) onto the adjusting screw (EE). Slide the thrust bearing assembly from step 1 onto the adjusting screw with the bearing side down. Step 3. Thread the aluminium bearing nut (FF) onto the adjusting screw from the bottom. Leave room below the bearing nut and thread a SS LH 1/2-20 jam nut (GG) below the bearing nut. The bearing nut and jam nut should be tightened against each other as shown in the Adjusting Screw Assembly Figure here below. Cap Assembly Spring Concentricity Test Step 1. Insert the finished adjusting screw assembly into the spring chamber. Fasten the tube cap to the inner tube with 4 Alloy 8-32 x 1/2 SHCS (LL) DD LL Lubricate Adjusting Screw (EE) EE Side View FF GG Side View of Adjusting Screw After Assembly FF GG Tighten the Faces of the Two Nuts (FF And GG) Against Each Other Adjusting Screw Assembly Bottom Surface of LH Jam Nut (GG) is Flush with Bottom of Adjusting Screw (EE) Insert Spring Assembly into Tube Step 2. Slide a 141 O-ring (MM) into the groove of the cartridge cap (NN). Step 3. Slide a 115 O-ring (OO) into the groove of the seal neck (PP). Step 4. Thread the seal neck into the cartridge cap. 18 GE Oil & Gas 2016 General Electric Company. All rights reserved.

21 PP OO NN MM TT SS RR Cap Assembly Step 5. Pull the adjusting screw up while threading the top cap assembly from step 4 counter-clockwise. After cap assembly is firmly engaged continue turning the adjusting screw clockwise while pushing the cap assembly down. You will feel a firm engagement of the cap assembly in place. At this time orient the cap assembly such that the mounting holes are in line with the pressure ports. Bolt the cap using 12, 1/4-20 x 3/4 HHCS (QQ). QQ Finalizing the FEP Assembly Pull the Adjusting Screw (EE) Up While Threading Cap Assembly from Step 4 Fastening the Cartridge Cap Step 6. Place the 7/16 SS thread seal (RR) and 7/16 SS flat washer (SS) onto the adjusting screw. After all the necessary adjustments on the FEP are made, thread the 7/16 SS jam nut (TT) onto the adjusting screw. Be careful not to overtighten the nut, doing so may cause damage to the adjusting screw itself. P1 P2 Complete FEP Assembly 2016 General Electric Company. All rights reserved. Becker FEP-1000/1500-CH Series Pilot Instruction Manual 19

22 List of Recommended Tools 1. Allen wrenches 9/64, 3/16, 1/8 2. Open wrenches 7/16, 3/4, 11/16, 5/16 3. Socket wrenches 3/8 drive, 7/16, 3/4 (Deepwell 12 Pt.) 4. Adjustable wrenches 6 5. Screwdrivers Phillips head, standard 6. Soft blow hammer 7. O-Ring pik 8. Pen (centering of diaphragm) 9. General assembly grease 10. 3/8 drive torque wrench Parts Silhouettes Fasteners, Nuts, and Washers (1:1 Scale) /4-20 x 3/4 SHCS ALLOY x 1/2 SHCS ALLOY /4-20 x 3/4 HHCS 316 SS /4-20 x 3 SHCS 316 SS /2-20 HEX JAM NUT 316 SS /16-20 JAM NUT 316 SS LH 1/2-20 HEX JAM NUT 316 SS SMALL WASHER ALUMINUM 2024-T /2-20 SPECIAL NUT ALUMINUM 2024-T PISTON SPACER ALUMINUM 2024-T GE Oil & Gas 2016 General Electric Company. All rights reserved.

23 Parts Silhouettes (Continued) O-Rings, Seal, and Additional Washers (1:1 Scale) O-RING -145 RUBBER FOR: SINGLE BODY & ADAPTER BLOCK O-RING -141 RUBBER FOR: CARTRIDGE CAP O-RING -115 RUBBER FOR: SEAL NECK O-RING -012 RUBBER FOR: SMALL PISTON & PISTONS W/SEAT O-RING -108 RUBBER FOR: ADJUSTING SCREW O-RING -010 RUBBER FOR: NOZZLE /16 FLAT WASHER 316 SS /16 THREAD SEAL PLATED STEEL W/RUBBER INSERT /4 I.D. X 1/2 O.D. WASHER FIBERGLASS 2016 General Electric Company. All rights reserved. Becker FEP-1000/1500-CH Series Pilot Instruction Manual 21

24 DIRECT SALES OFFICE LOCATIONS AUSTRALIA Brisbane: Phone: Fax: Perth: Phone: Fax: Melbourne: Phone: Fax : BELGIUM Phone: Fax: BRAZIL Phone: CHINA Phone: Fax: FRANCE Courbevoie Phone: Fax: GERMANY Ratingen Phone: Fax: INDIA Mumbai Phone: Fax: New Delhi Phone: Fax: ITALY Phone: Fax: JAPAN Tokyo Phone: Fax: KOREA Phone: Fax: MALAYSIA Phone: Fax: MEXICO Phone: THE NETHERLANDS Phone: Fax: RUSSIA Veliky Novgorod Phone: Fax: Moscow Phone: Fax: SAUDI ARABIA Phone: Fax: SINGAPORE Phone: Fax: SOUTH AFRICA Phone: Fax: SOUTH & CENTRAL AMERICA AND THE CARIBBEAN Phone: Fax: SPAIN Phone: Fax: UNITED ARAB EMIRATES Phone: Fax: UNITED KINGDOM Bracknell Phone: Fax: Skelmersdale Phone: Fax: UNITED STATES Massachusetts Phone: Fax: Corpus Christi, Texas Phone: Fax: Deer Park, Texas Phone: Fax: Houston, Texas Phone: Fax: *Denotes a trademark of the General Electric Company. Other company names and product names used in this document are the registered trademarks or trademarks of their respective owners General Electric Company. All rights reserved. GEA32451A 06/2016