Aakash Hydraulics

Kathwada, Ahmedabad, Gujarat

• Data Acquisition System for Test Records of Quarter Turn and Multi Turn Valves.
• Measurement of opening time, closing time, Dwell time at full open condition. Dwell time measurement at full close condition. Measurement of linear travel distance of valve stem.
• Display of no of cycles
• Adjustable forward and reverse speeds for opening/closing of valve.
• Measurement of torque during valve opening and closing at various angular position, different line pressure.
• Counter memory will be retained at the time of sudden power failure.
• Different models can be built up to suit different size and torque requirement.
• Prefilling pump ( optional ) for prefilling the valve before test
• Hydraulic Driven/ Air driven pump for high pressure built up of water.
• Pressure release solenoid / pneumatic actuated valve
• Suitable for angle flanged stop valve, straight way valve, straight way union, offset straight way union and other quarter turn valves
• High precision pressure sensor for line pressure measurement.
• The present model is suitable for 10 to 100 Nm / 5 to 25 RPM

Graphs / trends can be plotted for followings :

• Torque v/s percentage opening at a fixed line pressure
• Torque v/s line pressure

FEATURES:

• Stainless steel Test Cabinet with top open cover with rigid clamps and transparent poly carbonate sheet for test visualization
• Pressure regulators for adjustment of air test pressure and hydro test pressure
• Solenoid operated valves for air and water application
• Safety interlock for releasing pressure from test component when emergency push button is pressed
• Tower light indication for status of test . Green light when system is without pressure. Red light when component is under pressure.
• High Precision Pressure Sensor for feedback and display.
• Pneumatic cylinder for dipping the test component inside water and taking out of water when test is over ( holding time completed )
• Air operated pump for hydro burst test with water fluid
• Push Buttons for initiation of leak , burst test and up-down movement of test components.

FEATURES:

• Suitable for TATA-2515, TATA-2518, TATA 4018, TATA 1613, CUMMINS 250 KVA
• Radiator size : 790 mm x 560 mm x
• No compressive Load on Radiator Body. Flange to Flange type clamping system is adopted.
• Easy loading of radiator and Pneumatic clamping system for sealing between dummy sealing tank & body.
• Dipping of radiator in water to witness the leak test inside water tank by use of cylinders.
• Pneumatic system for imparting controlled air pressure and display of pressure holding time
• Different size of radiators can be covered in a single machine. Size Ranges from 300 mm to 1000 mm in width and height.
• Push Button Operation for carriage horizontal movement for matching with radiator height.
• Push Button Operation to dip the radiator inside water tank and take out the radiator from water after completion of test.

General Information :

• Our equipment have been designed to meet the requirements specified for hydro and burst test of brass Fittings of various sizes
• The equipment have been designed to be operated from a local HMI station for ease of operator and required display parameters are also available on HMI screen for better visualization and comfort.
• The hardware selected for the equipment are branded products with absolute reliability and consistent performance.

EQUIPMENT INFORMATION :

• A Hydro test cabinet of aluminium profile heavy duty sections for better ashthestics.
• Transparent poly carbonate sheets for better visualization
• SS water tank.
• Poly-carbonate door with safety interlocks during testing
• Fluid Test Media : Water with additives
• Highly Reliable Air Driven Pressure pump
• PLC for controlling operational sequence
• Ramp Rate control system
• Display of test pressure over HMI screen
• Display of status of operations on HMI
• Display of peak value of the burst pressure in case component bursts before reaching set value of pressure.
• Graphical Display of pressure v/s time curve on HMI screen

DATA ACQUISITION SYSTEM ( OPTIONAL )

• The automatic Data Acquisition System will be equipped with DAQ hardware to log data for burst pressure value automatically with the feedback from high precision pressure sensor.
• The customized Report with company Logo, cylinder serial no will be designed while generating test report.
• To generate and save customized reports in the computer, a PC based software and other required accessories will be included.
• This will help maintaining all the records inside the pc. USB / LAN can be used for communicating with test terminal for transferring the test reports to customer via internet.
• Pressure V/s time curve will be a part of customized test report which will have analytical values of Date/time stamp, pressure, time, total time before burst, and peak value at the time of bursting.

Our equipment have been designed to meet the requirements specified for hydro and burst test of electrical enclosure

The equipment have been designed to be operated from a local HMI station for ease of operator and required display parameters are also available on 10 HMI screen for better visualisation and comfort.

The hardware selected for the equipment are branded products with absolute reliability and consistent performance.EQUIPMENT INFORMATION :

A Hydro test cabinet of aluminium profile heavy duty sections for better ashthetics.Transparent poly carbonate sheets for better visualisationSS water tank for recollection of water after test.Polycarbonate door with safety interlocks during testingLow pressure prefilling pump for Quick filling of test enclosuresFluid Test Media : Water with additivesHighly Reliable Hydraulic Driven Pressure pumpPLC for controlling operational sequenceRamp Rate control systemDisplay of test pressure over HMI screenDisplay of status of operations on HMIDisplay of peak value of the burst pressure in case component bursts before reaching set value of pressure.Graphical Display of pressure v/s time curve on HMI screen

DATA ACQUISITION SYSTEM ( OPTIONAL )The automatic Data Acquisition System will be equipped with DAQ hardware to log data for burst pressure value automatically with the feedback from high precision pressure sensor.

The customized Report with company Logo, cylinder serial no will be designed while generating test report.

To generate and save customized reports in the computer, a PC based software and other required accessories will be included.

This will help maintaining all the records inside the pc. USB / LAN can be used for communicating with test terminal for transferring the test reports to customer via internet.

Pressure V/s time curve will be a part of customized test report which will have analytical values of Date/time stamp, pressure, time, total time before burst, and peak value at the time of bursting.

Special Model: ( Additional Features as per customers selection )
Fast/ slow system for controlling pressure over-shoot
Digital Display of Set pressure Value / Actual Pressure Value
Auto operated pressure Isolation Valve arrangement
Burst Point pick up in Digital Mode ( in case of Burst Test pump )
Provision of pressure release valve ( manual type )

• Our equipment have been designed to meet the requirements specified for hydro and burst test of brass Fittings of various sizes
• The equipment have been designed to be operated from a local HMI station for ease of operator and required display parameters are also available on HMI screen for better visualization and comfort.
• The hardware selected for the equipment are branded products with absolute reliability and consistent performance.

EQUIPMENT INFORMATION :

• A Hydro test cabinet of aluminium profile heavy duty sections for better ashthestics.
• Transparent poly carbonate sheets for better visualization
• SS water tank.
• Poly-carbonate door with safety interlocks during testing
• Fluid Test Media : Water with additives
• Highly Reliable Air Driven Pressure pump
• PLC for controlling operational sequence
• Ramp Rate control system
• Display of test pressure over HMI screen
• Display of status of operations on HMI
• Display of peak value of the burst pressure in case component bursts before reaching set value of pressure.
• Graphical Display of pressure v/s time curve on HMI screen

DATA ACQUISITION SYSTEM ( OPTIONAL )

• The automatic Data Acquisition System will be equipped with DAQ hardware to log data for burst pressure value automatically with the feedback from high precision pressure sensor.
• The customized Report with company Logo, cylinder serial no will be designed while generating test report.
• To generate and save customized reports in the computer, a PC based software and other required accessories will be included.
• This will help maintaining all the records inside the pc. USB / LAN can be used for communicating with test terminal for transferring the test reports to customer via internet.
• Pressure V/s time curve will be a part of customized test report which will have analytical values of Date/time stamp, pressure, time, total time before burst, and peak value at the time of bursting.

Our equipment have been designed to meet the requirements specified for hydro and burst test of electrical enclosure

The equipment have been designed to be operated from a local HMI station for ease of operator and required display parameters are also available on 10 HMI screen for better visualisation and comfort.

The hardware selected for the equipment are branded products with absolute reliability and consistent performance.EQUIPMENT INFORMATION :

A Hydro test cabinet of aluminium profile heavy duty sections for better ashthetics.Transparent poly carbonate sheets for better visualisationSS water tank for recollection of water after test.Polycarbonate door with safety interlocks during testingLow pressure prefilling pump for Quick filling of test enclosuresFluid Test Media : Water with additivesHighly Reliable Hydraulic Driven Pressure pumpPLC for controlling operational sequenceRamp Rate control systemDisplay of test pressure over HMI screenDisplay of status of operations on HMIDisplay of peak value of the burst pressure in case component bursts before reaching set value of pressure.Graphical Display of pressure v/s time curve on HMI screen

DATA ACQUISITION SYSTEM ( OPTIONAL )The automatic Data Acquisition System will be equipped with DAQ hardware to log data for burst pressure value automatically with the feedback from high precision pressure sensor.

The customized Report with company Logo, cylinder serial no will be designed while generating test report.

To generate and save customized reports in the computer, a PC based software and other required accessories will be included.

This will help maintaining all the records inside the pc. USB / LAN can be used for communicating with test terminal for transferring the test reports to customer via internet.

Pressure V/s time curve will be a part of customized test report which will have analytical values of Date/time stamp, pressure, time, total time before burst, and peak value at the time of bursting.

Standard Model :

Different Model to suit different test pressure requirement.Multi-stroking of IntensifierAnalog pressure Gauge for display of oil and water pressureUser Friendly, Low Maintenance SystemElectric control panel with RYB indication and Multi-stroking functionOil Pressure Regulator for increasing water test pressureArrangement of pressure holding and release is not included in standard model

Special Model: ( Additional Features as per customers selection )Fast/ slow system for controlling pressure over-shootDigital Display of Set pressure Value / Actual Pressure ValueAuto operated pressure Isolation Valve arrangementBurst Point pick up in Digital Mode ( in case of Burst Test pump )Provision of pressure release valve ( manual type )

MODEL NOManual/ Auto IR Max OutletPressure Bar ( PSI ) Min Outlet Pressure Bar ( PSI ) Free Dischargecc/ stroke Power3 Phase Power1 PhaseM 250 / A 250 1.8 250 ( 3570 PSI ) 15 ( 225 PSI ) 246 CC 1.5 HP 0.5 HPM 400 /A 400 3.6 400 ( 5712 PSI ) 20 ( 300 PSI ) 125 CC 1.5 HP 0.5 HPM 700 / A 700 3.6 700 ( 10000 PSI ) 20 ( 300 PSI ) 125 CC 2.0 HP 0.5 HPM 1000 / A 1000 5.8 1050 ( 15000 PSI ) 30 ( 450 PSI ) 125 CC 2.0 HP 0.5 HP

• Our equipment have been designed to meet the requirements specified for hydro and burst test of brass Fittings of various sizes
• The equipment have been designed to be operated from a local HMI station for ease of operator and required display parameters are also available on HMI screen for better visualization and comfort.
• The hardware selected for the equipment are branded products with absolute reliability and consistent performance.

EQUIPMENT INFORMATION :

• A Hydro test cabinet of aluminium profile heavy duty sections for better ashthestics.
• Transparent poly carbonate sheets for better visualization
• SS water tank.
• Poly-carbonate door with safety interlocks during testing
• Fluid Test Media : Water with additives
• Highly Reliable Air Driven Pressure pump
• PLC for controlling operational sequence
• Ramp Rate control system
• Display of test pressure over HMI screen
• Display of status of operations on HMI
• Display of peak value of the burst pressure in case component bursts before reaching set value of pressure.
• Graphical Display of pressure v/s time curve on HMI screen

DATA ACQUISITION SYSTEM ( OPTIONAL )

• The automatic Data Acquisition System will be equipped with DAQ hardware to log data for burst pressure value automatically with the feedback from high precision pressure sensor.
• The customized Report with company Logo, cylinder serial no will be designed while generating test report.
• To generate and save customized reports in the computer, a PC based software and other required accessories will be included.
• This will help maintaining all the records inside the pc. USB / LAN can be used for communicating with test terminal for transferring the test reports to customer via internet.
• Pressure V/s time curve will be a part of customized test report which will have analytical values of Date/time stamp, pressure, time, total time before burst, and peak value at the time of bursting.

EQUIPMENT DESCRIPTION:

The air operated pumping station will need 5 to 6 bar air pressure which will drive the pump to generate water pressure.The various models are available to cover up various output water press range.The unit is supplied with suitable air pressure regulator, analog pressure gauges for different pressure range, SS needle valves for isolation purpose, Water filtration system, prefill pump (optional), High pressure water storage accumulator to help avoid pulsating outlet flow (optional), movable skid- powder coated with suitable handle, as well as SS water Tank for suction requirement of pump unit, SS check valves and pneumatically operated isolation valve (optional).The output water pressure can be varied by varying the inlet air pressure. The major disadvantage of the unit is the availability of low discharge volume under load.

APPLICATIONS:

For Pressure/ burst testing of Castings, Valves, Hoses, and Pressure Vessels etc.Cyclic Pressure / life testing of Pressure Gauges, Pressure Switches, Hoses etc.Burst Strength Testing of pressurized vessels such as LPG / Nitrogen/ Oxygen gas cylinders, storage tanks, hoses, pipes etc.Seat leakage test of Control Valves.Operation of Single Acting Hydraulic Cylinders used in lifting platforms, hydraulic clamps, compression molding presses etc.Isotactic Pressing of powder metals and ceramics.Precise filling of liquid products such as soft drinks, juices, medicines etc. in packaging machinesTransferring of liquids from barrels, storage tank etc.Pumping oil or grease in centralized lubrication systems.Portable Systems for Construction, Mining & Defense Equipment

• Electric Motor 7.5 HP, 1450 RPM, 50 Hz
• Electric Consumption Per Hr. Approx. 5.59 Unit/hr

Pump :

• Triplex reciprocating pump, brass pump head, ceramic pistons, stainless steel valves and by-pass valve to unload the high pressure.
• Mounting SS Trolley (Closed Body)
• Weight Approx. 70 kgs
• Dimension (L x W x H) 28 x 23 x 18

Standard Accessories Supplied With the Equipment:

• High Pressure hoses 10 mtrs. Long with screw coupling both ends.
• Spray gun assembly
• Lance with V-Jet.
• PVC Nylon Breaded water Inlet Hose 5 meters long
• Electric Cable 5 meters long

Other information :

• Type : High Pressure Triplex Plunger Pump
• Required Suction Pressure : Flooded suction with max 2 bar
• Duty Cycle : Intermittent , 2 to 8 hours / day , & 5-10 min stop after every one hour
• Plunger surface finish : High Finish Ceramic ( < 0.25 Ra )
• Crank Shaft : Forged Alloy steel, Hardened and Ground

Customers Scope :

• Water utility line with minimum line pressure of 2-3 Bar

Water quality: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

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

papermill press section:

• a provision of stand-by unit will give flexibility to get switched over to the second pump-motor unit in the event of unforeseen eventuality of problem in primary pump-motor drive unit which will keep up the plant production and the problem can then be attended at ease without loss of production.
• no need to run the power-pack motor continuously. Our system design will help you save your power cost. The motor will consume power only for a duration which is needed to develop the required pressure and the pressure will then get maintained and motor will be powered off. Whenever needed it will automatically start the motor-pump unit for 2-3 minutes and again it will be powered off. So it will save running cost and eliminate unwanted heat generation of hydraulic oil which otherwise will deteriorate properties of hydraulic oil.
• no fear of burnt-out of solenoid coils during running of plants inviting downtime and expenditure towards managing the parts.
• 2-hp/3-hp / 5-hp power unit will be used depending on system design- requirement of nip load and type of leverage.
• independent pressure regulation at both ends is available through high precision pressure reducing valve of a reputed brand to achieve consistency of performance.
• highly reliable and branded hydraulic and electrical panel items for longer life and better performance
• digital controller , rital/ eldon enclosure, high precision gefran/ honeywell pressure transmitters, cromption electric motors, rexroth/ equivalent valves for nip load control, polyhydron valves for load/unload operation, schneider/ equivalent switch gear components shall be used in system construction

quick review:

• provision of stand by pump motor unit
• reduced down time
• inbuilt electrical control panel for selection of pump motor station.
• power saving
• no heating of oil thereby viscosity of oil is maintained for a longer duration
• user friendly , low maintenance system

hyd system for paper mill pope reel section

pope reel hydraulics :

• a provision of stand-by unit will give flexibility to get switched over to the second pump-motor unit in the event of unforeseen eventuality of problem in primary pump-motor drive unit which will keep up the plant production and the problem can then be attended at ease without loss of production.
• independent regulation of tension at both ends of secondary arm for pressing.
• 2 nos of locking cylinder + 2 nos of pressing cylinders.
• 2-hp power unit
• hand lever operation- no downtime because of coil burnt-out in case of power fluctuations.

quick review:

• provision of stand by pump motor unit
• reduced down time
• inbuilt electrical control panel for selection of pump motor station.
• no heating of oil thereby viscosity of oil is maintained for a longer duration
• user friendly , low maintenance system.

we can also supply hydraulic re-winder system for slitting line to suit your requirement

customer list :

• d.s. Pulp and paper machinery pvt ltd
• honest iron & engineering works.
• reliable paper mill-bardoli
• speciality paper mill-vapi
• rayana paper board industries ltd-gorakhpur
• bhagwatikrupa paper mill-jaipur
• shree ajit pulp & paper ltd-vapi
• hardoli paper mill-nagpur
• godawari pulp & paper mill ltd- nashik
• swastik paper mill-nashik
• venkraft paper mills pvt ltd- hosur
• kingston paptech pvt ltd-prantij ( gujarat )
• rama pulp & paper mill- vapi ( nath group )
• pinax paper mill- west bengal
• shree andal paper mill
• deoria paper mill
• shri hari paper indore
• best paper mill- vapi
• shree suyansh paper mill

Equipment Related Information :

• Closed Enclosure with poly-carbonate sheets for viewing from top as well as sides . Handle to lift the door. Rounded corners in fabrication to avoid injury to operator
• Electric control panel with push button operations
• Geared Motor with frequency drive control for soft start and stop.
• Safety mechanical locks in the top door
• Tower light red indication during machine operation.

EQUIPMENT INFORMATION :

• Single Screw Design with a movable seal head for height adjustment to suit the face length of valves.
• Vertical valve test orientation with stem Horizontal
• Hydraulic Clamp system with proportional clamping force adjustment as per the valve size and test pressure for face sealed valve types
• Non compressive for bore sealed valves
• Suitable for Gate , Globe, Ball and Butterfly Valves but without Actuator Assembly in case with control valves
• Test Media : High pressure water and Low Pressure Nitrogen Gas /Air
• Operators friendly machine
• Low Maintenance, Low floor space and robust machine
• Different Models to cover up the different range of valves to be tested.
• Provision of safety Guard for enhanced safety during test operations.
• For workshop/plant use.
• Easy, safe and accurate machine for testing the different types of valves
• Bubble jar for air seat leak tightness test
• Pressure Release Valves to release residual test pressure.
• Loading of valves from front.
• PLC for controlling the sequence of operations.

PROPORTIONAL CLAMPING:

• Hydraulic Proportional Clamping System to avoid excessive clamping force.
• Display of clamping force
• Safety Interlock to ensure that valve remains in clamped mode while under test pressure.

HYDRO SHELL TEST :

• Prefilling at Low Pressure water with air release
• High Pressure built up in valve as per the set value.
• Clamping force rise in proportion to the water pressure rise.
• Holding time, set pressure value as per the selection from HMI/ SCADA screen
• Release of pressure after test

HYDRO SEAT TEST :

• Prefilling at Low Pressure water with air release
• High Pressure built up in valve as per the set value.
• Clamping force rise in proportion to the water pressure rise.
• Holding time, set pressure value as per the selection from HMI/ SCADA screen
• Release of pressure after test
• Seat leak from both side of seat can be tested in the same valve test position ( optional feature )
• Manual collection of leak water for measurement

AIR SEAT TEST :

• Low Pressure Air as per the set value
• Holding time, set pressure value as per the selection from HMI/ SCADA screen
• Release of pressure after test
• Bubble Jar for witnessing seat leakage
• Seat leak from both side of seat can be tested in the same valve test position ( optional feature )

BORE SEALING :

• To be used for Butt weld end valves / Ball valves with machined bore.
• Special adapters are needed for bore sealed valves ( optional )
• No compressive force is transferred to valve body

DATA ACQUISITION SYSTEM :

• The automatic Data Acquisition System will be equipped with DAQ hardware to log data for set pressure value automatically and high precision pressure sensors and Digital Display.
• Alternatively, To generate and save customized reports in the computer, a PC based software and other required accessories will be included.
• This will help maintaining all the records inside the pc. USB / LAN can be used for communicating with test terminal for transferring the test reports to customer via internet.
• Automatic digital bubble counter also can be offered optionally for the leak tightness reports.

OPTIONAL :

• SCADA based DAQ system for report generation and report saving in a pc.
• Digital Bubble Counter for seat leak measurement
• Actuator operation system

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 )

ONLINE ASSEMBLY WITH TEST REPORTS
REJECTION BIN INTERLOCK
OPERATOR FRIENDLY PRESS
LOAD CELL FOR INDICATION OF AVAILABLE FORCE VALUE DURING ASSLY.
LVDT FOR MEASUREMENT OF DEPTH OF TRAVEL UNDER LOAD.
DISPLAY OF STATUS AND TEST RESULTS ON HMI SCREEN.

equipment related information

• stainless steel water tank for dipping the valve inside water during testing.
• pneumatic cylinder for clamp/ de clamp of the valve with foot pedal valve operation.
• pneumatic cylinder for dipping the valve into tank and taking it out of tank after tank.
• air pressure regulator system for test pressure with on-off valve.
• analog gauge to witness test pressure
• lighting arrangement for better view during leak test
• small schneider zelio plc system for auto operation
• reed switch sensors for position feedback.
• counters will be available for specified no of counts (32000 nos ) and then will get reset automatically.

customers scope :

• power supply with stabilizer
• low pressure air compressor

FEATURES:

• Pneumatic Cylinder will be used to impart required clamping force which can be regulated to suit the requirement of clamping force to suit size of valve under test.
• The valve shall be dipped inside water tank under clamped condition for testing of body leakage under air pressure.
• Air pressure inside body shall be applied on both sides one by one simply by pressing the relevant push button and keeping the opposite side needle valve in open condition to witness the seat leakage under air pressure.
• The valve seat shall be kept open during body test.
• The different sizes of valves can be tested in a single test bench
• Requirement of small floor space
• Operator friendly machine
• Test pressure can be adjusted by suitable pressure regulator.
• Supplied for double seat type gate valves to be tested at 80 PSIG.

General Information :

2 HP HYDRAULIC POWER-PACK FOR 5 T CAPACITY PRESS.4-PILLAR GUIDED MOVING TYPE FRAME FOR UNIFORM DISTRIBUTION OF LOAD.AUTO AND MAINTENANCE MODE SELECTION FROM PANEL. IN MAINTENANCE MODE, PLC OPERATION WILL BE BY-PASSED.PUSH BUTTONS FOR LOADING TABLE MOVEMENT.LOAD CELL WILL MEASURE THE AVAILABLE FORCE AND FEED THE INFORMATION TO PLC SYSTEM.LINEAR SCALE WILL MEASURE THE APPROACH AND PRESSING LENGTH AND GIVE FEEDBACK TO PLC SYSTEM.RAMP RATE SHALL BE CONTROLLED BY HYDRAULIC SYSTEM TO APPLY THE FORCE IN A LINEAR PATTERN.RITTAL ENCLOSURE WITH ALL THE ELECTRICAL PROTECTION SYSTEMS AND UTILITIES LIKE TUBELIGHT, COOLING FAN, EXTRA PLLUG SOCKET, GLASS FUSE TERMINALS, BARRIERS ETC.THE SELECTIVE ASSLY WILL BE SELECTED FROM HMI DROP DOWN MENU AND ALL THE REQUIRED PARAMETERS SHALL BE SET AUTOMATICALLY.PHOTOELECTRIC SENSORS SHALL HELP DETECT POSITION FOR THE DEPTH OF TRAVEL CONTROL.HIGH END PLC AND HMI MAKES THE SYSTEM RELIABLE AND ACCURATETOWERLIGHT INDICATION FOR IDENTIFYING THE TEST RESULTS: GREEN LIGHT FOR ACCEPTED ASSEMBLY, YELLOW LIGHT FOR RE-WORK ASSEMBLY AND RED LIGHT FOR REJECTED ASSEMBLY.NO DIMENSIONAL QUALITY CHECKS REQUIRED BEFORE ASSEMBLY FOR MAKING SELECTIVE ASSEMBLY.

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 )