Vertical Test Bench For Shut Off Valves

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 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-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 )