Valve Test Equipment

【Short Description】HJVTE-002 performs fully-automated set-pressure, re-seat, tightness and capacity verification of DN15–DN400 relief valves up to 48 MPa. A closed-loop servo booster delivers pressure ramps from 0.1 to 4 MPa·min⁻¹ while 10 kHz data acquisition pinpoints the exact pop point. Built-in libraries cover TSG ZF001-2006, GB/T 12242-2005, ASME PTC 25-2018 and API 527-2020; reports are digitally signed per 21 CFR Part 11 and exported via OPC-UA. 【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】 Dual-loop control: pneumatic-hydraulic clamping and test pressure regulated independently. 3-minute cartridge change-over: DN15–100, DN100–200, DN200–400 self-centering fixtures. 10 kHz data acquisition; pop-point detection uncertainty ≤0.02 %. Predictive maintenance: 28-parameter health index uploaded to cloud; MTBF ↑ 35 %. 21 CFR Part 11 compliant audit trail; electronic signatures and time-stamped event log. Digital twin included: firmware and calibration curves updated over-the-air, zero downtime. Nitrogen recovery loop reduces gas consumption by 38 %, pay-back <14 months. Noise ≤65 dB(A); suitable for indoor laboratories without acoustic enclosure. 【Applicable International Codes】 TSG ZF001-2006 Annex B4.2: set-pressure tolerance ≤±3 % GB/T 12242-2005 6.3: Class A tightness ≤20 bubbles/min GB/T 12241-2005 5.6: coefficient of discharge repeatability ≤2 % GB/T 12243-2005 8.2: mechanical characteristics three consecutive consistency tests ASME PTC 25-2018 4.2: pressure measurement uncertainty ≤0.25 % API 527-2020 Table 3: metal-seated leakage ≤20 bubbles/min IEC 61511-1:2016 11.9: proof-test interval for SIS final elements ≤12 months 【Applications】 Hydro-cracking hot-high-pressure relief valves Ethylene hyper-compressor bypass PRVs LNG high-pressure pump discharge pilot valves Nuclear SG safety and relief valves City-gate station RTZ slam-shut and relief combinations 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.

Factory-built PR2 validation rig for full-size API 6A gate valves. Performs hydrostatic strength, gas seat leakage, 200-cycle temperature endurance and switch-torque measurement in a single enclosure; PLC/PC control, 0.25 % F.S. pressure accuracy, calibration traceable to NIST.