Computer-Controlled Safety Valve Test Bench 48 MPa DN400 Spring
Pilot-Operated PRV Calibration Rig
【Product Description】
One-tenth of a bar deviation on a 40 MPa pilot-operated safety valve can flare an LNG train.
HJVTE-002 was engineered to remove that possibility.
A dual-loop PID controller separates hydraulic clamping force from test pressure, eliminating cross-talk. A 0.25 % accuracy, temperature-compensated quartz pressure transducer samples at 10 kHz; firmware locates the first derivative inflection to define lift-off within ±0.02 % F.S.
The bench automatically compensates for medium temperature (0–50 °C) and ambient humidity, then generates a tamper-proof PDF/XML certificate together with a QR-coded stainless-steel tag.
All high-pressure wetted parts are 316 L cold-worked stainless; valves, fittings and autoclave tubing are rated to 103 MPa (2 × working pressure) for indefinite fatigue life.
With CE, UKCA and Ex d ib IIB T4 certification the unit is ready for offshore, refinery and nuclear BOP applications.
【Key Features】
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Dual-loop control: pneumatic-hydraulic clamping and test pressure regulated independently.
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3-minute cartridge change-over: DN15–100, DN100–200, DN200–400 self-centering fixtures.
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10 kHz data acquisition; pop-point detection uncertainty ≤0.02 %.
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Predictive maintenance: 28-parameter health index uploaded to cloud; MTBF ↑ 35 %.
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21 CFR Part 11 compliant audit trail; electronic signatures and time-stamped event log.
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Digital twin included: firmware and calibration curves updated over-the-air, zero downtime.
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Nitrogen recovery loop reduces gas consumption by 38 %, pay-back <14 months.
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Noise ≤65 dB(A); suitable for indoor laboratories without acoustic enclosure.
【Applicable International Codes】
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TSG ZF001-2006 Annex B4.2: set-pressure tolerance ≤±3 %
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GB/T 12242-2005 6.3: Class A tightness ≤20 bubbles/min
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GB/T 12241-2005 5.6: coefficient of discharge repeatability ≤2 %
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GB/T 12243-2005 8.2: mechanical characteristics three consecutive consistency tests
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ASME PTC 25-2018 4.2: pressure measurement uncertainty ≤0.25 %
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API 527-2020 Table 3: metal-seated leakage ≤20 bubbles/min
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IEC 61511-1:2016 11.9: proof-test interval for SIS final elements ≤12 months
【Applications】
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Hydro-cracking hot-high-pressure relief valves
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Ethylene hyper-compressor bypass PRVs
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LNG high-pressure pump discharge pilot valves
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Nuclear SG safety and relief valves
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City-gate station RTZ slam-shut and relief combinations
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Pharmaceutical WFI sanitary relief valves
【Technical Specifications】
| Parameter |
Value |
| Max. valve size |
DN400 (16″) |
| Max. test pressure |
48 MPa (6,960 psi) |
| Pressure sensor accuracy |
±0.25 % F.S. (±0.1 % option) |
| Test media |
Nitrogen, compressed air, demineralised water |
| Clamping force range |
5–1,200 kN, repeatability ±2 % |
| Pressure ramp rate |
0.1–4 MPa·min⁻¹, servo-controlled |
| Data acquisition |
Pressure 10 kHz, lift 4 kHz |
| Power supply |
380 VAC 50 Hz 3 kW (110 V 60 Hz optional) |
| Foot-print |
2,800 × 1,200 × 1,800 mm |
| Weight |
1,850 kg |
| Operating temp. |
0–50 °C |
| Storage temp. |
–20–60 °C |
| Humidity |
5–95 % RH non-condensing |
| Control system |
Siemens S7-1500 + 15″ IPC |
| Communication |
OPC-UA, Modbus-TCP, Ethernet/IP |
| Report formats |
PDF, CSV, XML (21 CFR Part 11) |
| Calibration interval |
12 months |
| Enclosure rating |
IP54 |
| Ex certification |
Ex d ib IIB T4 (optional) |
| Noise level |
≤65 dB(A) |
| Fatigue life |
≥50,000 cycles clamping |
| Wetted material |
316 L CW, PTFE, FKM/EPDM |
| High-pressure components |
CEJN/HIP rated to 103 MPa |
| Certifications |
CE, UKCA, ISO 9001 |
【Valves Under Test】
Spring-loaded, balanced-bellows, pilot-operated, thermal relief, change-over, vacuum relief, rupture-disc/PRV combinations, cryogenic safety valves (–196 °C).
【Test Capabilities】
Set pressure, re-seat pressure, blowdown, seat tightness (bubble/drop), coefficient of discharge, lift measurement, back-pressure influence, cold-box leakage, cyclic fatigue, flow area verification.
