STB : Safety Relief Valve Test Bench 

  

GENERAL INFORMATION :

CLAMP TABLE :

Different Options available as per customer’s 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
  • High Pressure ( 200 Bar ) ( 300 Bar ) : Single Gas Booster Units to be incorporated
  • 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 customer’s end for positive suction /prefilling of valve )

TEST GAUGES : customer’s 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 ½” , ¾” , 1” , 1 ¼” , 1 ½” & 2 “
  • BSP ( Female ) Threads on valve body suitable for ½” , ¾” , 1” , 1 ¼” , 1 ½” & 2 “
  • NPT ( Male ) Threads on valve body suitable for ½” , ¾” , 1” , 1 ¼” , 1 ½” & 2 “
  • NPT ( Female ) Threads on valve body suitable for ½” , ¾” , 1” , 1 ¼” , 1 ½” & 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 ½” , ¾” , 1” , 1 ¼” , 1 ½” & 2 “
  • BSP ( Female ) Threads on valve body suitable for ½” , ¾” , 1” , 1 ¼” , 1 ½” & 2 “
  • NPT ( Male ) Threads on valve body suitable for ½” , ¾” , 1” , 1 ¼” , 1 ½” & 2 “
  • NPT ( Female ) Threads on valve body suitable for ½” , ¾” , 1” , 1 ¼” , 1 ½” & 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 ½” # 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 ½” # 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 0,1µ < d = 0,5µ = 100000/m³
  • particles density with the particle size of 0,5µ < d = 1,0µ = 1000/m³
  • particles density with the particle size of 1,0µ < d = 5,0µ = 10/m³
  • Humidity content: class 4
  • Pressure dew point = 3°C
  • Residual moisture = 6g/m³
  • Oil content: class 3 Total oil content =1,0 mg/m³ detected at 1 bar absolutely and 20°C 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 µm
  • Temperature 14°C