HTB : Horizontal Test Bench - Aakash Hydraulics

HTB : Horizontal Test Bench

Frame Type : 2 Pillar with Front cum Top Loading / Top Loading Type
Sealing Type : Hydraulic Cylinder with face sealing
Clamp Force Control : Auto Force Control
Operation Intrface : HMI
Valve Types : Shut off valves / Control Valves
End Connection : Flanged end / Non Flanged End for Butterfly Valves
Test Standards : API 598 , BS 1873
Pressure Class API : # 150, # 300, # 600, # 900, # 1500, # 2500
Pressure Class BS : PN-10, PN-16, PN-25, PN-40, PN-50, PN-60, PN-100, PN-160, PN-250, PN- 320, PN-400
Valve sizes : DN 15 – DN 300
Type of Valves : Gate Valve, Globe Valve, Ball Valve, Butterfly Valve

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 customer’s requirement of test parameters )
Digital Mass flow meter available as an option ( Range will be selected as per the customer’s 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

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 :

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 )