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Special Tests
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FCRI valve test facility covers all the tests to be performed on valves. This includes hydraulic tests, proof of design tests and special tests for specific customer requirements. Tests coming under proof of design and special tests are summerised below.
FCRI is equipped with all infrastructure required for fugitive emission testing of ON/OFF and control valves as pre ISO 15848 and ISA 93. The major equipment available with us include He mass spectrometer (ASM 142, Alkatel make), Temperature controllers with heater driver, Cryogenic tanks and flasks, Environment chamber (-70 – 200°C) and Furnace (700°C).
This has a capability of operability tests of valves with 350°C at 20 MPa with water as test medium. Valve leakage performance at elevated temperature and pressure can be evaluated with this facility. A unique feature of this facility is to cycle the operating pressure and temperature can be cycled. The operating pressure can be cycled between 20 Mpa to 0.5 MPa. Temperature can be cycled between 350C and ambient temperature.
A high pressure water lab with 7.5 MPa operating pressure and flow rate of 100 m3/h is under construction. This lab uses water as test medium with a maximum operating temperature of 70C. This facility can be used for cavitation studies on flow elements, estimation FL for control valves upto 4” size etc.
FCRI cavitation test facility is an extension of the high pressure test facility as described above with instrumentation for acquiring data for evaluating generation and propagation of cavitation in valves and pumps. This include 2D particle Image Velocimetry system, high speed camera, dynamic pressure transducers, accelerometers, piston phone, signal processing units.
PIV system
2 Dimensional PIV system employs Nd:Yag (Neodymium-doped Yttrium Aluminum Garnet; Nd:Y3Al5O12) laser sheet was used as the light source for flow visualisation. Nd:YAG lasers typically emit light with a wavelength of 1064 nm, in the infrared. A 2 Meg Pixel (MP) digital camera with 1 µsec. exposure time was used with associated software for capturing the image of the flow field. The laser source and the digital camera were synchronized using a synchronizer. During experimentation, laser sheet can made to fall on the flow visualisation section perpendicular to the valve stroke and the digital camera can be placed at the bottom of the test section.
The valve actuators can be tested for its proof of design tests. This include the load test, leakage tests, life cycle tests, Dynamic response tests apart from normal performance tests. Actuator can be testes as per AWWA / BS / DIN / ISO standards.
Here the valve or equipment will be subjected to maximum operating pressure in acyclic manner to ensure the operation of full life cycle of the valve. This test is being done as a prototype testing. The performance of the valve will be verified after the required number of operations of the valve. Failure analysis is also done with this facility.
Here the valve will be exposed to fire in the open condition until the valve body reaches a temperature of 600 C. This temperature will be maintained for a period not less than 15 minutes. The valve will be subjected to an internal pressure of 2 bar while exposed to fire. Valve leakage will be measured across the seat, gland, body joint and cover joint soon after the fire test. The standard followed for this tests include BS/ API/ AGA standards.
The valve or the equipment under test will be subjected to internal pressure as specified in the standard. The pressure will be increased at the rate of 20,000 psi per minute to the burst pressure (4/8 times the normal working pressure) or until burst or leak occurs. No leak or break should occur before burst pressure.
The test valve will placed inside a cryogenic chamber and will be cooled with liquid Nitrogen as the cooling media. The valve will be soaked in this environment for the specified period. The leakage characteristics of the valve will be studied after soaking. Valves upto 24” can be tested with our facility.
The valve / DUT will be place in a specially designed chamber with provision for hot air, steam and air supply. The DUT will be subjected to pressure and temperature with steam as test fluid simulating the failure of Main steam line. The performance of the equipment will be checked before and after the test. Provision is made for verifying the DUT performance during testing also.
The valve / DUT will be place in a specially designed chamber with provision for hot air, steam and air supply. The DUT will be subjected to pressure and temperature with steam as test fluid simulating the failure of Main steam line. The performance of the equipment will be checked before and after the test. Provision is made for verifying the DUT performance during testing also.
In this test, the actuator will be subjected to a torque equal or greater than twice the rated torque through one complete open – close cycle. After this the actuator will be subjected to cyclic loading for 10,000 cycles or less depending upon the size and capacity of the actuator. During cyclic loading rated torque is to be applied at the end of the strokes whereas a minimum of 30% rated torque will be applied at other positions. The actuator will be tested for any damage after torque cycling. It will also be subjected to a torque equal or greater than twice the rated torque through one complete open – close cycle.
Here the valve / equipment under test will be subjected to a pressure impulse varying between 10 bar and test pressure in the form of a pulse. The coupling is to be subjected to pressure impulse at a frequency of 0.5 – 1 Hz. The total no. of cycles will be specified by the customer. After each 10,000 cycles, the coupling is to be coupled 10 times. Leakage rate is to be measured at the end of the test.
The test item with process fluid inside will be heated to the required temperature with electric heaters at controlled rate. To keep the fluid inside in the liquid form, test item will pressurised to a pressure above saturation temperature. After heating, the system will be maintained at the test temperature for a specified period. Then, test item will be cooed to ambient temperature at the specified cooling rate. Heating will be done with electric heaters with proper temperature controllers. Cooling can be done with atmospheric cooling with forced draft. This will be done for specified number of cycles as specified in the standard.
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