Details
1. Product Overview
The Neometrix Valve Test Rig is a high-performance, hydraulic-based testing system specifically engineered to test Butterfly Valves and Check Valves ranging from 2 inches to 12 inches.
It is optimized for hydrostatic pressure testing, leak detection, body integrity validation, and seat verification in industrial production, maintenance, and quality control environments.
The rig uses a high-tonnage hydraulic press with programmable clamping and pressure regulation,
supported by an advanced power pack unit, safety interlocks, and a visual camera inspection
system.
2. Main Functional Objectives
• Validate valve shell strength against hydrostatic pressure.
• Detect seat leaks and body leaks using water (liquid medium).
• Enable rapid cycle testing for mass-production or maintenance environments.
• Guarantee operator safety with full interlock and emergency stop systems.
3. System Architecture and Components
| Subsystem |
Description |
| Hydraulic Press Bed |
Heavy-duty 65-ton 4-pillar vertical press for clamping valves. 400 mm stroke. |
| Power Pack Unit |
Dual-motor hydraulic source (7.5 HP & 2 HP) with dual pressure circuits, oil filtration, and cooling systems. |
| Controller Panel |
Digital control unit for setting clamping pressure (C1) and alarm thresholds (AL1). Emergency stop integration. |
| Leak Inspection Camera |
Industrial camera positioned under the valve to monitor and record leakage visually during tests. |
| Safety Interlock Systems |
Prevents claw release while under pressure; includes emergency stop and automatic motor cut-offs on fault detection. |
| Auxiliary Indicators |
Lights and alarms for system faults (filter clog, low oil level, motor trip). |
4. Detailed Technical Specifications
| Parameter |
Specification |
| Valve Type Supported |
Butterfly, Check Valves |
| Valve Size Range |
2” to 12” (DN50 to DN300) |
| Maximum Test Pressure |
135 Bar (1958 PSI) |
| Hydraulic Clamping Force |
65 Metric Tons |
| Motor Power |
7.5 HP (Clamping) + 2 HP (Loading) |
| Motor Type |
3-Phase Induction Motors, 4 Pole, 50 Hz, 415V |
| Hydraulic Fluid Filtration |
20 Micron Inline Filter, 10 Micron Return Line Filter |
| Pressure Control |
Relief Valves (Two-stage: 25 bar for clamping, 135 bar for loading) |
| Bed Stroke |
400 mm with reciprocating speed of 400 mm in ~45 seconds |
| Temperature Gauge |
0°C to 160°C (WIKA) |
| Pressure Sensors |
Mechanical Gauges and Pressure Transmitters |
| Operation Type |
Semi-automatic / Automatic |
5. Working Principle
The Valve Test Rig performs hydrostatic testing by clamping the valve between two hydraulic working plates, pressurizing it with liquid (typically water or a compatible hydraulic test fluid), and inspecting it for leaks or body deformation.
Step-by-Step Testing Operation:
1. Startup:
- Switch on the main power supply and the auxiliary system.
- Ensure hydraulic oil level is adequate; check filter health.
2. Clamping:
- Place the valve between the upper and lower working plates.
- Start the Clamping Motor (7.5 HP).
- Use the clamping cylinder to vertically lock the valve via hydraulic pressure (up to 25 bar).
3. Pressure Application:
- Start the Loading Motor (2 HP).
- Set the desired test pressure using controller parameters (C1 for desired, AL1 for alarm threshold).
- Adjust relief valves accordingly (for high pressure or low pressure tests).
4. Leak Detection:
- The leak camera positioned below visually monitors the valve body and seat for any seepage.
5. Unclamping and Test Completion:
- After test duration, pressure is released.
- Select UNCLAMP to retract the cylinder.
- Switch off the loading and clamping motors.
6. Capabilities
• Clamping Range: Single flange, dual flange, or proportional clamping.
• Pressure Testing Types:
- Shell (Body) Hydrostatic Test
- Seat Leakage Test
• Valve Material Compatibility: Suitable for metal-seated and rubber-seated valves.
• Test Medium: Water or test-compatible non-compressible liquids.
7. Construction and Material
• Main Frame: Rigid welded structure with heavy steel sections.
• Clamping Pillars: Hardened steel, designed for no-flex operation.
• Hydraulic Cylinders: High-precision, chrome-plated shafts with leak-proof seals.
• Filtration System: Hydac and Rexroth make, ensuring maximum fluid cleanliness.
• Cooling System: Radiator-based oil cooler to prevent fluid overheating in long operations.
8. Safety Features
• Emergency Stop Switches strategically placed.
• Claw Release Interlocks: Prevent mechanical movement under pressure.
• System Fault Indications: Motor overload, oil level drop, filter clogging.
• Pressure Relief Systems: Dual-stage relief for clamping and loading circuits.
• Operational Guidelines:
- No valve clamping without load application.
- Do not exceed the rated pressure (135 bar).
- Always confirm oil level and cleanliness before operation.
10. Optional Upgrades
• PLC-based Control System for test automation.
• Data Logging System (Test Pressure vs Time Graphs).
• Extended Pressure Range (up to 200 bar customization).
• Automatic Clamping Force Adjustment.
• Digital Leakage Quantification System (for precision R&D labs).
11. Applications
• Valve manufacturers for production batch testing.
• Oil & Gas industry for pipeline valve certification.
• Water supply utilities for valve maintenance and QA.
• Thermal and hydro power plants.
• Heavy engineering and EPC sectors requiring stringent hydro testing.
12. Compliance
• Designed in accordance with general principles of:
- API 598 Valve Testing Standard
- ISO 5208 Industrial Valve Pressure Testing
• Electrical systems compliant with IEC standards for industrial safety.
Conclusion:
The Neometrix Valve Test Rig offers an uncompromising balance of strength, accuracy, operational safety, and flexibility, making it ideal for companies seeking to improve their valve testing reliability, compliance, and throughput. Built rugged. Built smart. Built for industrial reliability.
