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

  • A system for providing 4-20 mA output signal ( Feeder for Valve Calibration )
  • 230V AC universal supply
  • 24VDC and 110 V AC power 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 )