Safety Relief Valve Test Bench

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
• 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