HYDRAULIC PRESSING WITH AUTO CLAMP FORCE CONTROL

General Information

  • Frame Type : 2 Pillar Rigid Frame
  • Design Type : Hydraulic Cylinder with face sealing
  • Seal Type : Face Seal
  • Clamp Force Control : Auto Force Control
  • Operational Interface : HMI Touch Screen Type
  • 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 ( without Actuator Assly )

Test Modules

Pre-filling

  • 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

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.

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

 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

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.

Test Bench 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

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 )

NATURAL PROPORTIONAL CLAMP FORCE

MAJOR ITEMS OF TEST RIG SUPPLY :

  • Valve Clamp Rig  :
  • Height Adjustment by Screw- Hydraulic Drive
  • Hydraulic Power pack Unit for Water Pressurizing Unit
  • Water Prefilling System ( Tap Water Supply by customer )
  • Water Pressurization System
  • Water Filtration System
  • Low Pressure Air Regulation ( Low pressure Dry Air supply by customer )
  • Instrument Control Panel
  • Electrical Panel with PLC and HMI Operational Interface

TYPE OF TESTS :  Ball Valve/ Plug Valve without Actuator

  • Hydro-shell
  • Hydro-Seat ( Uni-Directional )
  • LP Air Seat leak ( Uni- Directional )
  • Gland Leak Test

Features :

  • Rigid Structural Frame with high machining accuracy
  • Screw arrangement for valve soft clamping and   height adjustment
  • High Precision Pressure Transmitters for recording pressure drop of individual test piece during holding time
  • Stabilization and Holding time screens ( editable by authorized person ) over HMI screen
  • Upper pressure selection ( editable by authorized person ) over HMI screen
  • Operator friendly layout over HMI screen
  • Display of status of operation over HMI Screen which helps to diagnose
  • Water storage tank and fast prefill pump with level control arrangement
  • Semi Auto type operational sequence
  • Maintenance Mode
  • Overshooting of pressure is controlled by special hardware and supporting programming
  • Test results can be displayed in a graphical and analytical mode
  • Maintenance free oil lubricated intensifier system helps reduce down time to a great extent
  • Auto cutoff of pressure pump once set pressure is reached.
  • Manual Bubble Jar arrangement for witnessing seat leakage during air testing
  • Hydro-seat leak test to be witnessed by  manual drop counter system
  • Schneider PLC + HMI, Branded Switch gear components
  • User Friendly Operational Interface with standard recipe
  • Multi level password security
  • Semi skilled operator can operate the machine with a one day training

Safety

  • Multi-layer operational interface such as administrator , supervisor and user level controls
  • Safety screen Arrangement for test skid (Clear & hard Lexan window ) * ( available as option )
  • Red Tower light will be displayed when system is under pressure / yellow tower light when hydraulic system is on / Green or orange light is on when control panel is on
  • All tubing / Fittings / Hoses shall be hydro tested at 1.5 times working pressure
  • Emergency Stop button at panel side as well as machine side

UNIVERSAL VERTICAL VALVE TEST BENCH

General Information

  • Suitable For Testing of safety valve as well as shut-off valve for repair shop
  • Manual screw Drive / Auto screw Drive / Hydraulic Cylinder for adjustment of F to F valve dimensions
  • Shifting of top beam with Hand Lever while loading of the valve on the clamp table
  • Seat leakage location can be checked by clamping the valve with jaws and keeping top head away
  • Jaw clamping is feasible for flanged end valves only
  • Face sealing can be done by Pressing from Bottom Hydraulic Cylinder