becker* fep-1000/1500-ch series flexible element pilot · the fep-ch . measures downstream sensing...

Becker™

FEP-1000/1500-CH Series Flexible Element Pilot

Instruction Manual (Rev. C)

Baker Hughes Data Classification : Public

ii | Baker Hughes © 2021 Baker Hughes Company. All rights reserved.

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, BAKER HUGHES (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 BAKER HUGHES.

THE RIGHTS, OBLIGATIONS AND LIABILITIES OF BAKER HUGHES 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 BAKER HUGHES 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 BAKER HUGHES.

Becker FEP-1000/1500-CH Series Pilot Instruction Manual | 1© 2021 Baker Hughes Company. All rights reserved.

Table of Contents PageIntroduction ..........................................................................................................................1 Description ...................................................................................................................1 Scope of Manual ..........................................................................................................1 Model Number Explanation .........................................................................................1 Technical Assistance....................................................................................................1Technical Information..........................................................................................................2 Advantages of the Combination Chamber FEP-CH Pilot ............................................2 Technical Specifications...............................................................................................2 Materials of Construction .............................................................................................2 Applications .................................................................................................................2Ordering Information ...........................................................................................................3 FEP-CH Stock Numbers and Spring Ranges..............................................................3Accessories ..........................................................................................................................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 ........................................................................................4Principles of Operation .......................................................................................................5 Pressure Reducing Regulator Mode ...........................................................................5 Backpressure Regulator Mode ....................................................................................5 Explanation of Droop ...................................................................................................7Piping Schematics ..........................................................................................................9-10 Downstream Pressure Control ....................................................................................9 Backpressure Control ................................................................................................10Drawings ........................................................................................................................11-12 FEP-1000/1500-CH Pilot Spring Chamber ................................................................11 FEP-1000/1500-CH Sensing Chamber .....................................................................11 FEP-1000/1500-CH Body ..........................................................................................12 FEP-1000/1500-CH Bottom Cartridge .......................................................................12Assembly Procedures .................................................................................................13-19List of Recommended Tools .............................................................................................20Parts Silhouettes................................................................................................................20

IntroductionThe 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.

DescriptionThe 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 our commitment to continually develop new products and update existing ones to increase their performance while retaining simple operation and low maintenance.

Scope of ManualThis 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 ExplanationThe 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 Baker Hughes sales representative, sales office, or manufacturer before proceeding.

Technical AssistanceShould you have any questions, you may contact your local Baker Hughes sales representative or technical assistance at e-mail address appearing on the back cover page of this Manual.

2 | Baker Hughes © 2021 Baker Hughes Company. All rights reserved.

Technical InformationAdvantages of the Combination Chamber FEP-CH Pilot1. 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.

Table 2. Materials of ConstructionExternal Parts Anodized 2024 Aluminum/316 SS Available

Internal Parts 316 Stainless Steel and 2024 Anodized Aluminum

Springs Alloy Steel

Diaphragm Buna-N with nylon reinforcement

Seats and O-Rings Buna-N

Table 1. Technical SpecificationsSupply Gas Dry, Filtered (100 micron gas)

Maximum Flow Capacity See Cv Tables

Maximum Supply Pressure Inlet

1480 psig (10204 kPa)

Maximum ΔP 1000 psig (6895 kPa)

Maximum Sensing Pressure 1500 psig (10342 kPa)

Maximum Discharge Pres-sure Outlet

1300 psig (8963 kPa)

Maximum Bottom Chamber (for remote loading)

1500 psig (10342 kPa)

Operative Ambient Temperature Range

-20 to 160°F -29 to 71°C

Approximate Weight 6 pounds (2.7 kg)

Setpoint Range 550 psig - 1500 psig (3792 kPa - 10342 kPa)

Installation Orientation Vertical position recommended

Other Brands Becker FEP-CH

Figure 1. Schematic for the net force

Applications • Primary Pressure Control

• Overpressure Protection (Monitor)

• Underpressure Protection (Standby)

• Relief Valve

• Backpressure Control

• Power Plant Type Applications

Compatible Regulators • Redq Flexflo™

• American Meters Axialflow

• Fisher 399

• Mooney™ Flowgrid™


Ordering InformationWhen 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 (30-0039), Pressure Control Range 550-1000 psig (Yellow Spring , 25-1306), 1/8” Nozzle (25-1030), “M” Orifice Assembly (25-8162)

Table 4. FEP-1000/1500-CH Nozzle Information

Diameter Part No. Application

3/32” 25-1029 Gas

1/8” 25-1030 Liquid

FEP-CH Model Number Repair Kit Part #

FEP-1000-CH 30-9028

FEP-1500-CH 30-9028

FEP-1000-CH-NC 30-9028

FEP-1500-CH-NC 30-9028

Table 5. FEP-1000/1500-CH Orifice Part Information

Identifica-tion Stamp

Variable Ori-fice Assembly

Orifice Only Part Number

Standard (no stamp)

(25-1559) (25-1040)

“M” (25-8162) (25-8075)

“L” (25-8163) (25-8076)

Table 6. FEP-1000/1500-CH Repair Kit Part Information

FEP-CH Model No. Control Range (psig/kPa)

Spring Color (Part Number)

Setpoint Change per Revolution of Set-point 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)

550 – 1000 psig 3792 – 6895 kPa

Yellow (25-1306)

143 psig 990 kPa

700 psig 4826 kPa

700 psig 4826 kPa

FEP-1500-CH FEP-1500-CH-NC(1)

800 – 1300 psig 5516 – 8964 kPa

Grey (25-1562)

227 psig 1565 kPa

850 psig 5860 kPa

850 psig 5860 kPa

900 – 1500 psig 6205 – 10342 kPa

Violet (25-8073)

276 psig 1903 kPa

950 psig 6550 kPa

950 psig 6550 kPa

(1) NC = Normally Closed, for backpressure control.

Table 3. FEP-1000/1500-CH Control Spring and Setpoint Information


AccessoriesThe 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 Baker Hughes.

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. 4-20 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.

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.

Input Pressure Here


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

NOZZLE

OUT

MOLDED SEATFigure 3. Block turned upside down for back pressure applications.


Figure 2. FEP-1000-CH Principles of OperationPressure Reducing Regulator Mode.


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:P1 = pressure at inlet, P2 = pressure at outlet, AN = area of the nozzle, K = spring constant, DN = diameter of the nozzle, AD = area of the diaphragm

A simple force – balance equation in steady state shows:

(1) FD = FS + FN

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) FN = (P1 - P2) x AN = ΔP x AN

The force on the spring comes from the equation:

(3) FS = K x XWe 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 DN/4 inches from the nozzle opening. Therefore we know the maximum deflection of the spring is:

(4) X = DN/4

SPRING

DIAPHRAGM

FD = DIAPHRAGM FORCE

FS = SPRING FORCE

FN = NOZZLE FORCE

Since we know the given spring constant, K, for a yellow or gray spring: (5) FS = K x (DN/4)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) FD = PD x AD

So now our final equation for the maximum droop will be:

(7) PDMAX = (ΔP x AN + K x X)/ AD

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 = DN/4 either). Therefore we must multiply the ratio of the orifice and nozzle flow factors (CV) by the full lift distance (DN/4) in order to find the correct spring deflection, X for different intermediate seat positions.

(8) X (FOR INTERMEDIATE POSITIONS) = (CV ORIFICE/CV NOZZLE) x (DN/4)


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 Flow Direct

Opening Number0 1 2 3 4 5 6 7

“STD”Forward 0.003 0.004 0.009 0.026 0.042 0.071 0.099 0.122

Reverse 0.043 0.045 0.055 0.069 0.083 0.109 0.135 0.154

“M”Forward 0.043 0.046 0.063 0.090 0.135 0.173 0.212 0.250

Reverse 0.093 0.097 0.112 0.135 0.173 0.212 0.250 0.289

“L”Forward 0.043 0.062 0.173 0.327 0.462 0.577 0.635 0.674

Reverse 0.099 0.154 0.250 0.366 0.462 0.597 0.674 0.674

Table 7. Nozzle Diameter, Flow Factor (Cv), Nozzle Area, Diaphragm Area

Nozzle Diameter (in) Cv AN (in2) AD (in2)

3/32” 0.404 0.007 0.836

1/8” 0.635 0.012 0.836

Table 10. Results For Sample Pressure Droop Calculations (Psig)(1)

Nozzle Diameter (in) Spring Color

ΔP (psig)200 400 600 800 1000

3/32”Yellow 6.0 7.6 9.3 10.9 12.6

Grey 8.5 10.1 11.8 13.5 15.1

1/8”Yellow 6.6 9.5 12.5 15.4 18.3

Grey 8.7 11.7 14.6 17.6 20.5

Table 11. Results For Sample Pressure Droop Calculations (Bar)(1)

Nozzle Diameter (in) Spring Color

ΔP (psig)13.8 27.6 41.4 55.2 68.9

3/32”Yellow 0.4 0.5 0.6 0.8 0.9

Grey 0.6 0.7 0.8 0.9 1.0

1/8”Yellow 0.5 0.7 0.9 1.1 1.3

Grey 0.6 0.8 1.0 1.2 1.4

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.

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 CV of this nozzle is 0.404 and the nozzle area is 0.007 in2. 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 CV for a standard orifice set on #3 in the forward flow direction is 0.026. Finally, the effective diaphragm area of the FEP 1000/1500 CH pilots is given from Table 7 as 0.836 in2. Using the tables, we have found all the unknowns needed to solve for pressure droop, equation (7):

ΔP = 800 psig

AN = 0.007 in2

K = 2398 lbf/in

X = (0.026/0.404) x (0.09375/4) = 0.0015 in.

AD = 0.836 in2


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 SchematicsApplication #1Downstream Pressure Control

Flexible Element Regulator (Grove Flexflo 900TE shown)

FEP-1000/1500-CH NORMALLY OPEN

DOWNSTREAM SENSING LINE(1000 PSIG MAX FOR FEP-1000-CH,1500 PSIG MAX FOR FEP-1500-CH)

NOTE: REFER TO CV DATA FOR FORWARDAND REVERSE INSTALLATION

IN THE TECHNICAL DATA SECTION


FEP-1000/1500-CH NORMALLY CLOSED

UPSTREAM SENSING LINE(1000 PSIG MAX FOR FEP-1000-CH,1500 PSIG MAX FOR FEP-1500-CH)

Backpressure Control

Flexible Element Regulator (Grove Flexflo 900TE shown)

Piping SchematicsApplication #2


FEP-1000/1500-CH Pilot Spring Chamber Assembly

FEP-1000/1500-CH Sensing Chamber Assembly

Key Part No. Description1 30-7022 Adjusting Screw

2 98-2500 7/16-20” Jam Nut

3 30-7009 Seal Neck

4 95-2672 O-Ring - 108

5 95-2670 O-Ring - 115

6 95-2671 O-Ring - 141

7A 30-7007 Std. Tube Cap

7B 30-7026 Tube Cap Gray Spring

8A 25-1306 Yellow Spring

8B 25-1562 Gray Spring

9A 30-7006 Standard Bearing Case

9B 30-7027 Gray Spring Bearing Case

10 25-1062 Thrust Bearing

11 30-7001 Bearing Nut

12 98-3213 1/2-20” LH Jam Nut (316)

13 30-7003 Inner Tube

14 98-3231 1/4-20 x 3” SHCS (316 SS)

15 98-3181 7/16 FT Washer (SS)

16 30-7017 7/16 Thread Seal

17 98-3137 1/4-20” x 3/4” HHCS (SS)

18 98-3269 8-32 x 1/2” SHCS (Alloy)

19 30-7023 High Pressure Spring Cartridge

20 98-3227 .250 x .500” Washer (Fiberglass)

21 98-3229 1/4-20 x 1-1/2” SHCS (316 SS)

Key Part No. Description22 30-7016 Adapter Block

23 95-2665 O-Ring - 145

24 98-3056 1/2-20 Jam Nut (316)

25 30-7015 Thread Extension

26 30-7014 Small Washer

27 95-2615 O-Ring - 012

28 30-7058 Top Spacer

29 30-7011 Conv. Diaphragm w/ Hole

30 30-7010 Small Piston

1

15

16

17

18

19

20

21

2

345

6

7A, 7B

8A, 8B

9A, 9B

10

11

12

13

14

22

23

24

25

26

2730

29

28


FEP-1000/1500-CH Body Assembly

FEP-1000/1500-CH Bottom Cartridge Assembly

Key Part No. Description31 30-7078 Body Spacer

32 30-7011 Conv. Diaphragm W/Hole

33 30-7079 Piston w/Seat

34 95-2665 O-Ring - 145

35 98-3269 8-32 x 1/2” SHCS (Alloy)

36 30-7080 Piston Spacer

37 98-3056 1/2-20 Jam Nut (316)

38 30-7081 1/2-20 Special Nut

39 98-3285 1/4-20 x 3/4” SHCS (Alloy)

40 30-7077 Single Body

41A 25-1029 3/32” Nozzle

41B 25-1030 1/8” Nozzle

42 25-1023 Pilot Post

43 30-7014 Small Washer

Key Part No. Description44 98-3137 1/4-20 x 3/4” HHCS (SS)

45 30-7082 Modified Bottom Cartridge

31

32

33

3434

35

36

37

45

43

44

42

41A, 41B

40

39

38


A

D

G

D

C

C

H

F

G

E

E

H

B

C

P1

P1

P2

P2

Assembly ProceduresThe 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 Baker Hughes sales representative, sales office, or manufacturer before proceeding.

Single Body AssemblyStep 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.

Piston AssemblyStep 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).

Single Body Assembly

Complete Piston Assembly

Single Body O-Ring Assembly

Pilot Post - Piston Assembly

Body Spacer Assembly Step 1. Insert a –145 O-ring (H) into each groove of the single body (C).

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.


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 AssemblyStep 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 180-220 in.-lbs.

K

N (1/2-20 Aluminum)

O (1/2-20 SS)K

C

Piston Spacer (I) Side View Grooves Face

Up

Body Spacer (J) Side View

Piston Spacer (I) Side View

Grooves Face Down

Small Washer (M) Side View

Grooves Face Down

Diaphragm (L) Side View Convolute

Up

Diaphragm (L) Side View

Convolute Down

Body Spacer (J) Side View

Body Spacer Assembly Body Diaphragm Assembly

Small Washer (M) Side View

Grooves Face Up

P1

P2


Centering the DiaphragmsStep 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 AssemblyStep 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 100-110 in.-lbs.

Diaphragm Centering

Bottom Cartridge Assembly

P1

Step 1

Step 2

Q

P

Step 3P1

P1

P2

P2

P2

P2

P1


Assembling the Diaphragm

1000-1500-CH Chamber Assemblies

1000/1500-CH Adapter Block AssemblyInsert – 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 180-220 in.-lbs.

1000/1500-CH Bottom Spacer AssemblyOrient 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 rotat-ed 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

Connecting the Two Pistons

1000/1500-CH Diaphragm AssemblySlide – 012 O-ring (A) onto the small piston (B). Place the dia-phragm 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 180-220 in.-lbs.


1000/1500 Spring Chamber AssemblyFasten 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).

Bolting the Spring Chamber


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).

Press Fit Thrust Bearing and Bearing Case

Adjusting Screw Assembly

Spring Concentricity Test

Insert Spring Assembly into Tube

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

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)

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.

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.CC

AA

DD

Side View

Side View of Adjusting Screw After Assembly

Bottom Surface of LH Jam Nut (GG) is Flush with

Bottom of Adjusting Screw (EE)

Tighten the Faces of the Two Nuts (FF And GG)

Against Each Other

EE

FF

FF

GG

GG

BB

HH or II

Lubricate Adjusting

Screw (EE)

LL

JJ


Fastening the Cartridge Cap

Cap Assembly

Finalizing the FEP Assembly

Complete FEP 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).

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.

Note: Be careful not to overtighten the nut, doing so may cause damage to the adjusting screw itself.

PP

NN

OO

MM

Pull the Adjusting Screw (EE) Up While Threading Cap Assembly from Step 4

QQ

P2P1

TT

SS

RR


List of Recommended Tools1. 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 SilhouettesFasteners, Nuts, and Washers (1:1 Scale)

98-32311/4-20 x 3 SHCS

316 SS

98-32851/4-20 x 3/4 SHCS

ALLOY

98-30561/2-20 HEX JAM NUT

316 SS

98-3213LH 1/2-20 HEX JAM NUT

316 SS

30-70811/2-20 SPECIAL NUT

ALUMINUM 2024-T351

30-7014SMALL WASHER

ALUMINUM 2024-T351

30-7080PISTON SPACER

ALUMINUM 2024-T351

98-25007/16-20 JAM NUT

316 SS

98-32698-32 x 1/2 SHCS

ALLOY

98-31371/4-20 x 3/4 HHCS

316 SS


Parts Silhouettes (Continued) O-Rings, Seal, and Additional Washers (1:1 Scale)

95-2665O-RING -145

RUBBERFOR: SINGLE BODY &

ADAPTER BLOCK

95-2671O-RING -141

RUBBERFOR: CARTRIDGE CAP

95-2670O-RING -115

RUBBERFOR: SEAL NECK

95-2615O-RING -012

RUBBERFOR: SMALL PISTON &

PISTONS W/SEAT

95-2672O-RING -108

RUBBERFOR: ADJUSTING

SCREW

95-2609O-RING -010

RUBBERFOR: NOZZLE

98-31817/16 FLAT WASHER

316 SS

30-70177/16 THREAD SEALPLATED STEEL W/RUBBER INSERT

98-32271/4 I.D. X 1/2 O.D. WASHER

FIBERGLASS

Tech Field Support & Warranty:Phone: +1-866-827-5378

[email protected]

bakerhughes.com

Copyright 2021 Baker Hughes Company. All rights reserved. Baker Hughes provides this information on an “as is” basis for general information purposes. Baker Hughes does not make any representation as to the accuracy or completeness of the information and makes no warranties of any kind, specific, implied or oral, to the fullest extent permissible by law, including those of merchantability and fitness for a particular purpose or use. Baker Hughes hereby disclaims any and all liability for any direct, indirect, consequential or special damages, claims for lost profits, or third party claims arising from the use of the information, whether a claim is asserted in contract, tort, or otherwise. Baker Hughes reserves the right to make changes in specifications and features shown herein, or discontinue the product described at any time without notice or obligation. Contact your Baker Hughes representative for the most current information. The Baker Hughes logo, Flexflo, Mooney and Flowgrid are trademarks of Baker Hughes Company. Other company names and product names used in this document are the registered trademarks or trademarks of their respective owners.

BHBK-FEP-1000-1500-CH-IOM-32451C-0421 04/2021

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