Different Options available as per customers selection :

• Manual T- Bolt Type clamp Table
• Hydraulic Cylinder and Hydraulic Hand pump for clamping the valve
• Hydraulic Cylinder and Power pack unit with local push button
• 3/4 /6 Sliding Jaw design
• Knob type clamping force adjustment valve with pressure gauge for hydraulic clamp table
• Different sizes of clamp Tables for different range of valve inlet flange rating and pressure ratings

TEST FLUID MEDIA :

SELECTION-1 : TESTING BY AIR :

Pressure source :

• Low Pressure ( 0-25 Bar ) / Medium Pressure ( 0-60 Bar ) / High Pressure ( 0-330 Bar ) Compressor unit
• On/ off controls for compressor unit
• Suitable Air Receiver Tank with manual / auto drain valve
• Safety Valve for Air Receiver
• Pressure Gauge
• Isolation valves
• Air Dryer Unit

Control section :

• High Precision Needle valves for leak tightness and pressure release
• Inlet side isolation valves
• Ball valves for pop up function ( if required )
• Non Return Valves
• Fabricated control panel
• Fabricated Floor
• Air Filter
• Bubble Jar Arrangement

SELECTION-2 : TESTING BY NITROGEN :

Pressure source :

• Low Pressure ( 0-25 Bar ) / Medium Pressure ( 0-60 Bar ) : Nitrogen Bottles are recommended
• Very High Pressure ( 400 Bar ) ( 600 Bar ) : Double Gas Booster units to be incorporated
• Booster Drive Air compressor unit with Air receiver Tank, Safety valve, on off controls, Drain Valve, Pressure Gauge , Isolation Valves , Air Dryer Unit , Filters and required items

Control section :

• High Precision Needle valves for leak tightness and pressure release
• Inlet side isolation valves
• Ball valves for pop up function ( if required )
• Non Return Valves
• Fabricated control panel
• Fabricated Floor
• High Pressure filter
• Bubble Jar Arrangement

SELECTION-3 TESTING BY WATER :

Pressure source :

• Air Driven Pump unit / Oil Driven Pump Unit
• Storage vessel
• Cut off system
• Water Booster pump Drive Air compressor unit with Air receiver Tank, Safety valve, on off controls, Drain Valve, Pressure Gauge , Isolation Valves , Air Dryer Unit , Filters and required items

Control section :

• High Precision Needle valves for leak tightness and pressure release
• Inlet side isolation valves
• Ball valves for pop up function ( if required )
• Non Return Valves
• Fabricated control panel
• Fabricated Floor
• Tap water filter( Tap water with 2-3 bar pressure will be required from customers end for positive suction /prefilling of valve )

TEST GAUGES : customers selection

Standard Test Gauges : +/- 0.5 % FSD , 100 mm Dial

• 0-10 Bar
• 0-28 Bar
• 0-60 Bar
• 0-100 Bar
• 0- 160 Bar
• 0-280 Bar
• 0-400 Bar
• 0-600 Bar
• Additional Port for connection with Master Gauge

STANDARD ACCESSORIES :

• Sealing plates for RF valves
• Outer flange / bubble test flanges for RF flanges
• C clamp for outer flange

OPTIONAL ACCESSORIES :

Adaptor Plates :

• BSP ( Male ) Threads on valve body suitable for , , 1 , 1 , 1 & 2
• BSP ( Female ) Threads on valve body suitable for , , 1 , 1 , 1 & 2
• NPT ( Male ) Threads on valve body suitable for , , 1 , 1 , 1 & 2
• NPT ( Female ) Threads on valve body suitable for , , 1 , 1 , 1 & 2
• Metic ( Female ) Threads on valve body suitable for M6x1 , M 8 x1.25 , M 10 x 1.5 , M12 x 1.75 , M 16 x 2 , M20 x 2, 5 , M 24 x 3 , M30 x 3.5 & M 36 x 4
• Metic ( Male ) Threads on valve body suitable for M6x1 , M 8 x1.25 , M 10 x 1.5 , M12 x 1.75 , M 16 x 2 , M20 x 2, 5 , M 24 x 3 , M30 x 3.5 & M 36 x 4

Outer Plugs :

• BSP ( Male ) Threads on valve body suitable for , , 1 , 1 , 1 & 2
• BSP ( Female ) Threads on valve body suitable for , , 1 , 1 , 1 & 2
• NPT ( Male ) Threads on valve body suitable for , , 1 , 1 , 1 & 2
• NPT ( Female ) Threads on valve body suitable for , , 1 , 1 , 1 & 2
• Metic ( Female ) Threads on valve body suitable for M6x1 , M 8 x1.25 , M 10 x 1.5 , M12 x 1.75 , M 16 x 2 , M20 x 2, 5 , M 24 x 3 , M30 x 3.5 & M 36 x 4
• Metic ( Male ) Threads on valve body suitable for M6x1 , M 8 x1.25 , M 10 x 1.5 , M12 x 1.75 , M 16 x 2 , M20 x 2, 5 , M 24 x 3 , M30 x 3.5 & M 36 x 4

RTJ Seal Plates :

• Inlet Sealing plates for RTJ valves for 1 # 150 / # 300 /# 600 /#900 /# 1500 /# 2500
• Inlet Sealing plates for RTJ valves for 2 # 150 / # 300 /# 600 /#900 /# 1500 /# 2500
• Inlet Sealing plates for RTJ valves for 2 # 150 / # 300 /# 600 /#900 /# 1500 /# 2500
• Inlet Sealing plates for RTJ valves for 3 # 150 / # 300 /# 600 /#900 /# 1500 /# 2500
• Inlet Sealing plates for Tonged Grooved Valves ( customized )

COMPUTER REGISTRATION SYSTEM / DAQ :

High Speed DAQ

• Computer pc / laptop system
• NI Data Acquisition Software
• NI Data Acquisition Hardware
• Precision Pressure sensors for recording pressure values
• Communication cables
• Bubble counter with sensors

Low Speed DAQ

• Computer pc / laptop system
• SCADA Data Acquisition Software
• PLC Data Acquisition Hardware
• Precision Pressure sensors for recording pressure values
• Communication cables
• Bubble counter with sensors

UTILITY REQUIREMENT :

POWER REQUIREMENT :

• 3 Phase, 440 V , 50 Hz with Neutral and Earth
• For Driving the Air compressor unit
• For Operating Hydraulic Power Unit
• 1 phase, 230 V AC, 50 Hz with Neutal and Earth connection :
• Stabilized power preferably with UPS system for feeding power to control , instruments and Computer

UTILITY AIR :

• Low pressure utility air for cleaning purpose / instrument air to be arranged by customer.

General Guidelines :

Drive air quality Requirement :

• The drive air should correspond to ISO 8573-1, purity classes 2 / 4 / 3.
• Solid impurities: class 2 max. particles density with the particle size of 0, 1 < d = 0, 5 = 100000/m
• particles density with the particle size of 0, 5 < d = 1, 0 = 1000/m
• particles density with the particle size of 1, 0 < d = 5, 0 = 10/m
• Humidity content: class 4
• Pressure dew point = 3C
• Residual moisture = 6g/m
• Oil content: class 3 Total oil content =1, 0 mg/m detected at 1 bar absolutely and 20C With the given compressed air quality an optimum lifetime of the seals and bushings is reached.

TAP WATER CONNECTION :

• Should have 2-3 bar line pressure for effective suction for water pressurizing pump

Water quality Requirement :

• Besides the general characteristics of the water according to the requirements for potable water, the following recommendations can be given from practical experience to prevent corrosion and to reduce furring:
• ph-value 7 to 8, 5 the water has to be in balance of lime and Carbon dioxide which means it shall not contain self aggressive iron carbon dioxide
• Carbonate hardness 6 to 15 dH
• Chlorid content of < 100 mg/l Cl shall be reached
• Filter accuracy 20 m
• Temperature 14C

control valve test modules :

module-ht1 : vacuum system

• this will be useful for quick pre filling of test valve by way of evacuation the complete valve cavity before pre filling is started
• this will help eliminate compression of residual air inside valve and help increase sealing life and hazardous way of escaping trapped air outside forcibly.
• the system will include a suitable vacuum pump, moisture receiver tank with drain valve, hose pipe, vacuum gauge/ sensor and isolation valve for vacuum line.

module-ht2 : prefill system

• mainly used for water prefilling inside valve before pressurization and after soft clamping of valve body
• low pressure prefilling pump arrangement for prefilling of valve before test
• water tank with level controller and drain valve.
• water filtration and recirculation system
• safety bypass valve

module-ht3 : high pressure hydro shell test

• hydro shell test with high pressure water to suit the different pressure class of the valve under test
• hydraulic power driven pump which is highly reliable, self lubricated and less maintenance prone has a larger discharge capacity to built up required pressure in a reasonable time compared to air driven hydro-pneumatic pumps.
• dual speed design for better control over pressure.
• hydraulic driven high pressure pump, cartridge filters, suction and discharge nrv and accessories.

module-ht4 : high pressure hydro seat test

• required pressure will be applied from pressure source available .
• pressure drop to be observed.
• seat leak in a flow direction of a valve. Pressurization from both side available as option

module-ht5 : low pressure air seat test system

• dry utility air at 7 bar inlet air pressure shall be provided by customer for this test
• air regulator, pressure transmitter, solenoid valve , nrv etc will be incorporated
• seat leak in a flow direction of a valve. Pressurization from both side available as option

module-ht6 : high pressure air test system ( optional )

• provision of high pressure air compressor suitable for generating test pressure upto 300 bar ( 4500 psi ) and suitable for testing of valves upto 200 bar ( 3000 psi ), with high pressure reservoirs for storage and test pressure control needle valves/ gauges and other required hardware.

module-hc1 : low pressure air seat leak detection and measurement system

• rotameters of various ranges with isolation ball valves for air seat leak measurement ( range will be selected as per the customers requirement of test parameters )
• digital mass flow meter available as an option ( range will be selected as per the customers requirement of test parameters )
• bubble jar arrangement for visualization of seat leak for very small amount of leakages across seat.
• digital bubble counter available as an option for visualization of seat leak for very small amount of leakages across seat

module-hc2 : seat leak testing arrangement by water

• required pressure will be applied from pressure source available .
• measurement of leakage through seat shall be done manually by collecting the same in a marked beaker from the non pressurized side of seat.

actuator operations :

module-ac1 : pneumatic actuator operating system

• a system for providing air pressure for signal ( 0-20 psi )/ afr for 3-15 psi with panel mounted gauge with gauge saver ( signal pressure )
• a system for providing inlet air to actuator ( 0-100 psi ) / afr 0-85 psi with panel mounted gauge and regulator
• a system for cyclic operation of air actuator / pneumatic cyclic operation with editable holding time ( double solenoid pneu valve )

module-ac2 : electric actuator operating system

• a system for providing 4-20 ma output signal ( feeder for valve calibration )
• 230v ac universal supply
• 24vdc and 110 v acpower supply
• provision to provide 24 v dc / 230 v ac power connection

general information :

test skid :

• horizontal mounting of valves with stem in a vertical orientation- valve mounting position as piped in most situation + ease of loading and unloading of valves.
• most suitable design for valves with as well as without actuator assembly
• suitable for face sealing of flanged end and socket end/ screwed end valves.
• robust, safe and operator friendly machine
• the rated capacity of test skid is the maximum reaction force the skid is designed for. ( please refer model chart for selection )
• the 2 pillar frame is designed for better space for visual inspection and loading.
• the common sealing plates with o-rings for face sealing of certain range of valve sizes and pressure class.

hydraulic clamping

• hydraulic auto force control clamping system to avoid excessive clamping force over valve body.
• provision of inching type button to increase the clamp force
• display of clamp force on hmi/ scada screen.
• safety interlock to keep the valve in clamped position while it is under test pressure
• provision for local soft clamp , clamp force inching and de-clamp push button
• high precision, reliable pressure transmitter for feedback of oil pressure
• various interlocks for enhanced safety of operator and equipment

auxiliary functions :

• hydraulic intensifier system with controls for smooth rise of pressure and avoiding over shooting of pressure beyond predefined overshooting pressure limits.
• valve center height support vertical movement
• valve center height support horizontal movement
• auto isolation of prefill line ( optional )
• auto decompression ( optional )

instrument control panel :

• hydro shell test with high pressure water to suit the different pressure class of the valve under test
• our machines have been classified as 160 bar, 250 bar, 400 bar and 650 bar maximum rated pressure
• low pressure prefilling pump arrangement for prefilling of valve before test
• water tank with level controller and drain valve.
• water filtration and recirculation system
• manual air and pressure relieving valves
• high pressure water generation and control system
• air seat pressurization system and components for 7 bar
• pressure transducers for feedback and digital display

lp air seat leak test :

• bubble jar arrangement for visualization of seat leak
• visual seat leak arrangement is available
• digital bubble counter available as an option

plc control panel :

• electric control panel with reputed components such as mcb, smps, relays, contactors, signal conditioners, isolators etc
• cooling fan, tube lights, additional plug sockets , filters
• standard enclosure
• plc hardware components
• plc will control the operational sequence and display the status of operations on hmi
• will control the clamping force with integration of hydraulics and pressure sensors
• standard recipes on hmi for ease of operator
• display of test results on hmi
• editable stabilization and holding time

daq system ( optional )

• a normal pc or ipc ( optional ) for maintaining the test reports
• reports can be saved in an excel format / pdf format
• customized test reports with company logo and pattern can be designed and incorporated.
• scada licence software with hardware lock
• designing of scada screens and programming for operators interface.
• reports can be saved and printed as per the requirement and can be transferred to another pc by lan or by mail.
• test results in graphical and analytical mode
• ms acess / my sql database ( optional )
• odbc compatible database format required in case of integration with sap system ( optional )

shut off valve test modules:

module-vt1 : prefill system

• mainly used for water prefilling inside valve before pressurization and after soft clamping of valve body
• low pressure prefilling pump arrangement for prefilling of valve before test
• water tank with level controller and drain valve.
• water filtration and recirculation system
• safety bypass valve

module-vt2 : high pressurehydro shell test

• hydro shell test with high pressure water to suit the different pressure class of the valve under test
• hydraulic power driven pump which is highly reliable, self lubricated and less maintenance prone has a larger discharge capacity to built up required pressure in a reasonable time compared to air driven hydro-pneumatic pumps.
• dual speed design for better control over pressure.
• hydraulic driven high pressure pump, cartridge filters, suction and discharge nrv and accessories.

module-vt3 : low pressure air seat test system

• dry utility air at 7 bar inlet air pressure shall be provided by customer for this test
• air regulator, pressure transmitter, solenoid valve , nrv etc will be incorporated
• bubble jar arrangement for visualization of seat leak for very small amount of leakages across seat.
• digital bubble counter available as an option for visualization of seat leak for very small amount of leakages across seat
• seat leakage as per flow direction of valve. Pressurization from both side also available as option

module-vt4 :hydro seat leak test

• required pressure will be applied from pressure source available .
• pressure drop will be observed
• seat leakage as per flow direction of valve. Pressurization from both side also available as option

module-vt5 : high pressure air test system ( optional )

• provision of high pressure air compressor suitable for generating test pressure upto 300 bar ( 4500 psi ) and suitable for testing of valves upto 200 bar ( 3000 psi ), with high pressure reservoirs for storage and test pressure control needle valves/ gauges and other required hardware.

general information :

test skid :

• vertical mounting of valves with stem in a horizontal orientation- ideal for prefilling of valve.
• most suitable design for valves without actuator assembly
• suitable for face sealing of flanged end and socket end/ screwed end valves.
• robust, safe and operator friendly machine
• the rated capacity of test skid is the maximum reaction force the skid is designed for. ( please refer model chart for selection )
• the 2 pillar frame is designed for better space for visual inspection and loading.
• the common sealing plates with o-rings for face sealing of certain range of valve sizes and pressure class.

hydraulic clamping

• hydraulic auto force contol clamping system to avoid excessive clamping force over valve body.
• provision of inching type button to increase the clamp force
• display of clamp force on hmi/ scada screen.
• safety interlock to keep the valve in clamped position while it is under test pressure

auxiliary functions :

• hydraulic intensifier system with controls for smooth rise of pressure and avoiding over shooting of pressure beyond predefined overshooting pressure limits.
• auto isolation of prefill line ( optional )
• auto decompression ( optional )

instrument control panel :

• hydro shell test with high pressure water to suit the different pressure class of the valve under test
• our machines have been classified as 160 bar, 250 bar, 400 bar and 650 bar maximum rated pressure
• low pressure prefilling pump arrangement for prefilling of valve before test
• water tank with level controller and drain valve.
• water filtration and recirculation system
• manual air and pressure relieving valves
• high pressure water generation and control system
• air seat pressurization system and components for 7 bar
• pressure transducers for feedback and digital display

lp air seat leak test :

• bubble jar arrangement for visualization of seat leak
• visual seat leak arrangement is available
• digital bubble counter available as an option

plc control panel :

• electric control panel with reputed components such as mcb, smps, relays, contactors, signal conditioners, isolators etc
• cooling fan, tube lights, additional plug sockets , filters
• standard rittal/ eldon/ equivalent quality enclosure
• plc hardware components
• plc will control the operational sequence and display the status of operations on hmi
• will control the clamping force with integration of hydraulics and pressure sensors
• standard recipes on hmi for ease of operator
• display of test results on hmi
• editable stabilization and holding time

daq system ( optional )

• a normal pc or ipc ( optional ) for maintaining the test reports
• reports can be saved in an excel format / pdf format
• customized test reports with company logo and pattern can be designed and incorporated.
• scada licence software with hardware lock
• designing of scada screens and programming for operators interface.
• reports can be saved and printed as per the requirement and can be transferred to another pc by lan or by mail.
• test results in graphical and analytical mode
• ms acess / my sql database ( optional )
• odbc compatible database format required in case of integration with sap system ( optional )

Different Options available as per customers selection :

• Manual T- Bolt Type clamp Table
• Hydraulic Cylinder and Hydraulic Hand pump for clamping the valve
• Hydraulic Cylinder and Power pack unit with local push button
• 3/4 /6 Sliding Jaw design
• Knob type clamping force adjustment valve with pressure gauge for hydraulic clamp table
• Different sizes of clamp Tables for different range of valve inlet flange rating and pressure ratings

TEST FLUID MEDIA :

SELECTION-1 : TESTING BY AIR :

Pressure source :

• Low Pressure ( 0-25 Bar ) / Medium Pressure ( 0-60 Bar ) / High Pressure ( 0-330 Bar ) Compressor unit
• On/ off controls for compressor unit
• Suitable Air Receiver Tank with manual / auto drain valve
• Safety Valve for Air Receiver
• Pressure Gauge
• Isolation valves
• Air Dryer Unit

Control section :

• High Precision Needle valves for leak tightness and pressure release
• Inlet side isolation valves
• Ball valves for pop up function ( if required )
• Non Return Valves
• Fabricated control panel
• Fabricated Floor
• Air Filter
• Bubble Jar Arrangement

SELECTION-2 : TESTING BY NITROGEN :

Pressure source :

• Low Pressure ( 0-25 Bar ) / Medium Pressure ( 0-60 Bar ) : Nitrogen Bottles are recommended
• Very High Pressure ( 400 Bar ) ( 600 Bar ) : Double Gas Booster units to be incorporated
• Booster Drive Air compressor unit with Air receiver Tank, Safety valve, on off controls, Drain Valve, Pressure Gauge , Isolation Valves , Air Dryer Unit , Filters and required items

Control section :

• High Precision Needle valves for leak tightness and pressure release
• Inlet side isolation valves
• Ball valves for pop up function ( if required )
• Non Return Valves
• Fabricated control panel
• Fabricated Floor
• High Pressure filter
• Bubble Jar Arrangement

SELECTION-3 TESTING BY WATER :

Pressure source :

• Air Driven Pump unit / Oil Driven Pump Unit
• Storage vessel
• Cut off system
• Water Booster pump Drive Air compressor unit with Air receiver Tank, Safety valve, on off controls, Drain Valve, Pressure Gauge , Isolation Valves , Air Dryer Unit , Filters and required items

Control section :

• High Precision Needle valves for leak tightness and pressure release
• Inlet side isolation valves
• Ball valves for pop up function ( if required )
• Non Return Valves
• Fabricated control panel
• Fabricated Floor
• Tap water filter( Tap water with 2-3 bar pressure will be required from customers end for positive suction /prefilling of valve )

TEST GAUGES : customers selection

Standard Test Gauges : +/- 0.5 % FSD , 100 mm Dial

• 0-10 Bar
• 0-28 Bar
• 0-60 Bar
• 0-100 Bar
• 0- 160 Bar
• 0-280 Bar
• 0-400 Bar
• 0-600 Bar
• Additional Port for connection with Master Gauge

STANDARD ACCESSORIES :

• Sealing plates for RF valves
• Outer flange / bubble test flanges for RF flanges
• C clamp for outer flange

OPTIONAL ACCESSORIES :

Adaptor Plates :

• BSP ( Male ) Threads on valve body suitable for , , 1 , 1 , 1 & 2
• BSP ( Female ) Threads on valve body suitable for , , 1 , 1 , 1 & 2
• NPT ( Male ) Threads on valve body suitable for , , 1 , 1 , 1 & 2
• NPT ( Female ) Threads on valve body suitable for , , 1 , 1 , 1 & 2
• Metic ( Female ) Threads on valve body suitable for M6x1 , M 8 x1.25 , M 10 x 1.5 , M12 x 1.75 , M 16 x 2 , M20 x 2, 5 , M 24 x 3 , M30 x 3.5 & M 36 x 4
• Metic ( Male ) Threads on valve body suitable for M6x1 , M 8 x1.25 , M 10 x 1.5 , M12 x 1.75 , M 16 x 2 , M20 x 2, 5 , M 24 x 3 , M30 x 3.5 & M 36 x 4

Outer Plugs :

• BSP ( Male ) Threads on valve body suitable for , , 1 , 1 , 1 & 2
• BSP ( Female ) Threads on valve body suitable for , , 1 , 1 , 1 & 2
• NPT ( Male ) Threads on valve body suitable for , , 1 , 1 , 1 & 2
• NPT ( Female ) Threads on valve body suitable for , , 1 , 1 , 1 & 2
• Metic ( Female ) Threads on valve body suitable for M6x1 , M 8 x1.25 , M 10 x 1.5 , M12 x 1.75 , M 16 x 2 , M20 x 2, 5 , M 24 x 3 , M30 x 3.5 & M 36 x 4
• Metic ( Male ) Threads on valve body suitable for M6x1 , M 8 x1.25 , M 10 x 1.5 , M12 x 1.75 , M 16 x 2 , M20 x 2, 5 , M 24 x 3 , M30 x 3.5 & M 36 x 4

RTJ Seal Plates :

• Inlet Sealing plates for RTJ valves for 1 # 150 / # 300 /# 600 /#900 /# 1500 /# 2500
• Inlet Sealing plates for RTJ valves for 2 # 150 / # 300 /# 600 /#900 /# 1500 /# 2500
• Inlet Sealing plates for RTJ valves for 2 # 150 / # 300 /# 600 /#900 /# 1500 /# 2500
• Inlet Sealing plates for RTJ valves for 3 # 150 / # 300 /# 600 /#900 /# 1500 /# 2500
• Inlet Sealing plates for Tonged Grooved Valves ( customized )

COMPUTER REGISTRATION SYSTEM / DAQ :

High Speed DAQ

• Computer pc / laptop system
• NI Data Acquisition Software
• NI Data Acquisition Hardware
• Precision Pressure sensors for recording pressure values
• Communication cables
• Bubble counter with sensors

Low Speed DAQ

• Computer pc / laptop system
• SCADA Data Acquisition Software
• PLC Data Acquisition Hardware
• Precision Pressure sensors for recording pressure values
• Communication cables
• Bubble counter with sensors

UTILITY REQUIREMENT :

POWER REQUIREMENT :

• 3 Phase, 440 V , 50 Hz with Neutral and Earth
• For Driving the Air compressor unit
• For Operating Hydraulic Power Unit
• 1 phase, 230 V AC, 50 Hz with Neutal and Earth connection :
• Stabilized power preferably with UPS system for feeding power to control , instruments and Computer

UTILITY AIR :

• Low pressure utility air for cleaning purpose / instrument air to be arranged by customer.

General Guidelines :

Drive air quality Requirement :

• The drive air should correspond to ISO 8573-1, purity classes 2 / 4 / 3.
• Solid impurities: class 2 max. particles density with the particle size of 0, 1 < d = 0, 5 = 100000/m
• particles density with the particle size of 0, 5 < d = 1, 0 = 1000/m
• particles density with the particle size of 1, 0 < d = 5, 0 = 10/m
• Humidity content: class 4
• Pressure dew point = 3C
• Residual moisture = 6g/m
• Oil content: class 3 Total oil content =1, 0 mg/m detected at 1 bar absolutely and 20C With the given compressed air quality an optimum lifetime of the seals and bushings is reached.

TAP WATER CONNECTION :

• Should have 2-3 bar line pressure for effective suction for water pressurizing pump

Water quality Requirement :

• Besides the general characteristics of the water according to the requirements for potable water, the following recommendations can be given from practical experience to prevent corrosion and to reduce furring:
• ph-value 7 to 8, 5 the water has to be in balance of lime and Carbon dioxide which means it shall not contain self aggressive iron carbon dioxide
• Carbonate hardness 6 to 15 dH
• Chlorid content of < 100 mg/l Cl shall be reached
• Filter accuracy 20 m
• Temperature 14C

control valve test modules :

module-ht1 : vacuum system

• this will be useful for quick pre filling of test valve by way of evacuation the complete valve cavity before pre filling is started
• this will help eliminate compression of residual air inside valve and help increase sealing life and hazardous way of escaping trapped air outside forcibly.
• the system will include a suitable vacuum pump, moisture receiver tank with drain valve, hose pipe, vacuum gauge/ sensor and isolation valve for vacuum line.

module-ht2 : prefill system

• mainly used for water prefilling inside valve before pressurization and after soft clamping of valve body
• low pressure prefilling pump arrangement for prefilling of valve before test
• water tank with level controller and drain valve.
• water filtration and recirculation system
• safety bypass valve

module-ht3 : high pressure hydro shell test

• hydro shell test with high pressure water to suit the different pressure class of the valve under test
• hydraulic power driven pump which is highly reliable, self lubricated and less maintenance prone has a larger discharge capacity to built up required pressure in a reasonable time compared to air driven hydro-pneumatic pumps.
• dual speed design for better control over pressure.
• hydraulic driven high pressure pump, cartridge filters, suction and discharge nrv and accessories.

module-ht4 : high pressure hydro seat test

• required pressure will be applied from pressure source available .
• pressure drop to be observed.
• seat leak in a flow direction of a valve. Pressurization from both side available as option

module-ht5 : low pressure air seat test system

• dry utility air at 7 bar inlet air pressure shall be provided by customer for this test
• air regulator, pressure transmitter, solenoid valve , nrv etc will be incorporated
• seat leak in a flow direction of a valve. Pressurization from both side available as option

module-ht6 : high pressure air test system ( optional )

• provision of high pressure air compressor suitable for generating test pressure upto 300 bar ( 4500 psi ) and suitable for testing of valves upto 200 bar ( 3000 psi ), with high pressure reservoirs for storage and test pressure control needle valves/ gauges and other required hardware.

module-hc1 : low pressure air seat leak detection and measurement system

• rotameters of various ranges with isolation ball valves for air seat leak measurement ( range will be selected as per the customers requirement of test parameters )
• digital mass flow meter available as an option ( range will be selected as per the customers requirement of test parameters )
• bubble jar arrangement for visualization of seat leak for very small amount of leakages across seat.
• digital bubble counter available as an option for visualization of seat leak for very small amount of leakages across seat

module-hc2 : seat leak testing arrangement by water

• required pressure will be applied from pressure source available .
• measurement of leakage through seat shall be done manually by collecting the same in a marked beaker from the non pressurized side of seat.

actuator operations :

module-ac1 : pneumatic actuator operating system

• a system for providing air pressure for signal ( 0-20 psi )/ afr for 3-15 psi with panel mounted gauge with gauge saver ( signal pressure )
• a system for providing inlet air to actuator ( 0-100 psi ) / afr 0-85 psi with panel mounted gauge and regulator
• a system for cyclic operation of air actuator / pneumatic cyclic operation with editable holding time ( double solenoid pneu valve )

module-ac2 : electric actuator operating system

• a system for providing 4-20 ma output signal ( feeder for valve calibration )
• 230v ac universal supply
• 24vdc and 110 v acpower supply
• provision to provide 24 v dc / 230 v ac power connection

general information :

test skid :

• horizontal mounting of valves with stem in a vertical orientation- valve mounting position as piped in most situation + ease of loading and unloading of valves.
• most suitable design for valves with as well as without actuator assembly
• suitable for face sealing of flanged end and socket end/ screwed end valves.
• robust, safe and operator friendly machine
• the rated capacity of test skid is the maximum reaction force the skid is designed for. ( please refer model chart for selection )
• the 2 pillar frame is designed for better space for visual inspection and loading.
• the common sealing plates with o-rings for face sealing of certain range of valve sizes and pressure class.

hydraulic clamping

• hydraulic auto force control clamping system to avoid excessive clamping force over valve body.
• provision of inching type button to increase the clamp force
• display of clamp force on hmi/ scada screen.
• safety interlock to keep the valve in clamped position while it is under test pressure
• provision for local soft clamp , clamp force inching and de-clamp push button
• high precision, reliable pressure transmitter for feedback of oil pressure
• various interlocks for enhanced safety of operator and equipment

auxiliary functions :

• hydraulic intensifier system with controls for smooth rise of pressure and avoiding over shooting of pressure beyond predefined overshooting pressure limits.
• valve center height support vertical movement
• valve center height support horizontal movement
• auto isolation of prefill line ( optional )
• auto decompression ( optional )

instrument control panel :

• hydro shell test with high pressure water to suit the different pressure class of the valve under test
• our machines have been classified as 160 bar, 250 bar, 400 bar and 650 bar maximum rated pressure
• low pressure prefilling pump arrangement for prefilling of valve before test
• water tank with level controller and drain valve.
• water filtration and recirculation system
• manual air and pressure relieving valves
• high pressure water generation and control system
• air seat pressurization system and components for 7 bar
• pressure transducers for feedback and digital display

lp air seat leak test :

• bubble jar arrangement for visualization of seat leak
• visual seat leak arrangement is available
• digital bubble counter available as an option

plc control panel :

• electric control panel with reputed components such as mcb, smps, relays, contactors, signal conditioners, isolators etc
• cooling fan, tube lights, additional plug sockets , filters
• standard enclosure
• plc hardware components
• plc will control the operational sequence and display the status of operations on hmi
• will control the clamping force with integration of hydraulics and pressure sensors
• standard recipes on hmi for ease of operator
• display of test results on hmi
• editable stabilization and holding time

daq system ( optional )

• a normal pc or ipc ( optional ) for maintaining the test reports
• reports can be saved in an excel format / pdf format
• customized test reports with company logo and pattern can be designed and incorporated.
• scada licence software with hardware lock
• designing of scada screens and programming for operators interface.
• reports can be saved and printed as per the requirement and can be transferred to another pc by lan or by mail.
• test results in graphical and analytical mode
• ms acess / my sql database ( optional )
• odbc compatible database format required in case of integration with sap system ( optional )

shut off valve test modules:

module-vt1 : prefill system

• mainly used for water prefilling inside valve before pressurization and after soft clamping of valve body
• low pressure prefilling pump arrangement for prefilling of valve before test
• water tank with level controller and drain valve.
• water filtration and recirculation system
• safety bypass valve

module-vt2 : high pressurehydro shell test

• hydro shell test with high pressure water to suit the different pressure class of the valve under test
• hydraulic power driven pump which is highly reliable, self lubricated and less maintenance prone has a larger discharge capacity to built up required pressure in a reasonable time compared to air driven hydro-pneumatic pumps.
• dual speed design for better control over pressure.
• hydraulic driven high pressure pump, cartridge filters, suction and discharge nrv and accessories.

module-vt3 : low pressure air seat test system

• dry utility air at 7 bar inlet air pressure shall be provided by customer for this test
• air regulator, pressure transmitter, solenoid valve , nrv etc will be incorporated
• bubble jar arrangement for visualization of seat leak for very small amount of leakages across seat.
• digital bubble counter available as an option for visualization of seat leak for very small amount of leakages across seat
• seat leakage as per flow direction of valve. Pressurization from both side also available as option

module-vt4 :hydro seat leak test

• required pressure will be applied from pressure source available .
• pressure drop will be observed
• seat leakage as per flow direction of valve. Pressurization from both side also available as option

module-vt5 : high pressure air test system ( optional )

• provision of high pressure air compressor suitable for generating test pressure upto 300 bar ( 4500 psi ) and suitable for testing of valves upto 200 bar ( 3000 psi ), with high pressure reservoirs for storage and test pressure control needle valves/ gauges and other required hardware.

general information :

test skid :

• vertical mounting of valves with stem in a horizontal orientation- ideal for prefilling of valve.
• most suitable design for valves without actuator assembly
• suitable for face sealing of flanged end and socket end/ screwed end valves.
• robust, safe and operator friendly machine
• the rated capacity of test skid is the maximum reaction force the skid is designed for. ( please refer model chart for selection )
• the 2 pillar frame is designed for better space for visual inspection and loading.
• the common sealing plates with o-rings for face sealing of certain range of valve sizes and pressure class.

hydraulic clamping

• hydraulic auto force contol clamping system to avoid excessive clamping force over valve body.
• provision of inching type button to increase the clamp force
• display of clamp force on hmi/ scada screen.
• safety interlock to keep the valve in clamped position while it is under test pressure

auxiliary functions :

• hydraulic intensifier system with controls for smooth rise of pressure and avoiding over shooting of pressure beyond predefined overshooting pressure limits.
• auto isolation of prefill line ( optional )
• auto decompression ( optional )

instrument control panel :

• hydro shell test with high pressure water to suit the different pressure class of the valve under test
• our machines have been classified as 160 bar, 250 bar, 400 bar and 650 bar maximum rated pressure
• low pressure prefilling pump arrangement for prefilling of valve before test
• water tank with level controller and drain valve.
• water filtration and recirculation system
• manual air and pressure relieving valves
• high pressure water generation and control system
• air seat pressurization system and components for 7 bar
• pressure transducers for feedback and digital display

lp air seat leak test :

• bubble jar arrangement for visualization of seat leak
• visual seat leak arrangement is available
• digital bubble counter available as an option

plc control panel :

• electric control panel with reputed components such as mcb, smps, relays, contactors, signal conditioners, isolators etc
• cooling fan, tube lights, additional plug sockets , filters
• standard rittal/ eldon/ equivalent quality enclosure
• plc hardware components
• plc will control the operational sequence and display the status of operations on hmi
• will control the clamping force with integration of hydraulics and pressure sensors
• standard recipes on hmi for ease of operator
• display of test results on hmi
• editable stabilization and holding time

daq system ( optional )

• a normal pc or ipc ( optional ) for maintaining the test reports
• reports can be saved in an excel format / pdf format
• customized test reports with company logo and pattern can be designed and incorporated.
• scada licence software with hardware lock
• designing of scada screens and programming for operators interface.
• reports can be saved and printed as per the requirement and can be transferred to another pc by lan or by mail.
• test results in graphical and analytical mode
• ms acess / my sql database ( optional )
• odbc compatible database format required in case of integration with sap system ( optional )