SALIENT FEATURES OF K.MASS TEST BENCHES

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Annabella Parks
5 years ago
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All in all K.Mass Valve Test Equipment is packaged with a great deal of special features that make it the most sought after by Industries worldwide.

All liquid, gas as well as vacuum systems are built & Integrated in a closed Independent Control Console provided with adequate access from both front & Rear sides for easy maintenance The Consoles

1 All in all K.Mass Valve Test Equipment is packaged with a great deal of special features that make it the most sought after by Industries worldwide. All Standard and Optional features available in our Test Equipment are designed, configured & integrated to guarantee Accurate Test Results, Optimal Output, Operator & Environment Safety and Absolute User-friendliness. Ergonomic Controls & Instrumentation - Housing & Controls for all Test Systems are ergonomically designed to ensure Optimum performance & output, whilst maintaining high standards of Safety. All liquid, gas as well as vacuum systems are built & Integrated in a closed Independent Control Console provided with adequate access from both front & Rear sides for easy maintenance The Consoles doors have perforations to allow necessary air circulation to prevent discharged over heating in the High Pressure Pumps & Boosters. All hand operated valves & controls are mounted on a tapered steel tray on the front side of the console below average shoulder level, while all visible instrumentation like analogue pressure gauges & digital read outs are mounted on the front vertical face of the console at average eye level.. This provides the user effortless access to all manual controls & clear visibility of all Instrumentation read outs. Page 1 of 7

All Controls & Instrumentation are appropriately tagged & labeled for easy identification & workflow. Test & Valve Specific Clamping Systems - All Clamping Systems manufactured by K.

Depending on the desired application, quantum of testing & user skill level, customers are free to choose a Single or a Combination Clamping Assembly from a variety of Seat and / or Body test systems

This mounting plate is coupled to an Auto clamping unit comprising of a SS-Piston, pressure chamber and an SS spring.

2 All Controls & Instrumentation are appropriately tagged & labeled for easy identification & workflow. Test & Valve Specific Clamping Systems - All Clamping Systems manufactured by K.Mass are urbanely designed & configured especially to reduce loading and unloading time in between testing of various valves / assemblies. Depending on the desired application, quantum of testing & user skill level, customers are free to choose a Single or a Combination Clamping Assembly from a variety of Seat and / or Body test systems options below:- Seat Test Systems Auto Clamping Assembly Hydraulic Clamping Assembly This system comprises of a thick mounting plate with a set of sliding clamps mounted on the table. This mounting plate is coupled to an Auto clamping unit comprising of a SS-Piston, pressure chamber and an SS spring. The system design enables the operator to quick clamp a valve without the use of any gaskets or bolting. The Piston pushes the Intermediate Flange against the test valve flange face, which in turn pulls the clamp arms tight against the opposite side of the flange. When the required Test Pressure is generated, the valve is firmly clamped applying the clamping force only to the valve flange and not the valve body. This keeps the body safe from any compression load during seat leakage test. It is a fail-safe clamping wherein the clamping force is a direct multiple of the test pressure. In simple words, the clamping force automatically increases with the increase in test pressure. This system comprises of a set of sliding clamps mounted on a T-Slot table coupled with an Independent Hydraulic Pressure System. This Hydraulic System is installed with dedicated PLC operated Power-pack which is controlled by a Remote. The system design enables the operator to quick clamp a valve without the use of any gaskets or bolting. Each Clamping Assembly is equipped with a Safety Interlock System to Prevent the Clamping Pressure from being De-pressurized while a Valve is under Test It is a fail-safe clamping wherein depending on the Size / Class Rating of the Valve under Test; the clamping force can be varied by the means of Touch Screen HMI. Page 2 of 7

Body Test Systems - Manual Lead Screw type Clamping Assembly Hydraulic Clamping Assembly This is a manually operated press type clamping arrangement for body test of valves.

Once the valve is in position for clamping, the user manually operates the hand wheel to clamp the valve for pressurization.

A rigid carbon steel top plate housing a Hydraulic Load cylinder is mounted atop vertical columns on the test port.

3 Body Test Systems - Manual Lead Screw type Clamping Assembly Hydraulic Clamping Assembly This is a manually operated press type clamping arrangement for body test of valves. A rigid carbon steel top plate housing a geared hand wheel assembly with a heavy duty load spindle is mounted atop vertical columns on the test port. Once the valve is in position for clamping, the user manually operates the hand wheel to clamp the valve for pressurization. Extended torque handles enable the user to clamp the valve securely with bare minimum physical effort. This is a hydraulic operated press type clamping arrangement for body test of valves. A rigid carbon steel top plate housing a Hydraulic Load cylinder is mounted atop vertical columns on the test port. This Hydraulic System is installed with dedicated PLC operated Power-pack which is controlled by a Remote. Each Clamping Assembly is equipped with a Safety Interlock System to Prevent the Clamping Pressure from being De-pressurized while a Valve is under Test It is a fail-safe clamping wherein depending on the Size / Class Rating of the Valve under Test; the clamping force can be varied by the means of Touch Screen HMI. Multiple Test Arrangements - There are numerous types of valves in the industry installed in many different orientations for which one of the test parameters is simulation of the actual installation orientation. Also certain valve types like flapper type check valves & Gate Valves may differ in recommended test orientation as compared to Safety Relief, Globe & Ball valves. To suit object specific test orientation, customer may choose from any of the following Test Arrangements: - Vertical Suitable for almost all types of valves, this is the most commonly seen universal test arrangement. This type of an arrangement ensures easy loading / unloading of valves as well as quick removal of air pockets prior to pressurization. This arrangement covers all size ranges for seat test of valves. However, for body test, this arrangement is suitable for valve sizes up to 6 only (which can be lifted & mounted manually). This is because larger valves require a hoist to be mounted in place; where in the vertical arrangement for body test obstructs the access. Page 3 of 7

Horizontal Tilting Though mostly suitable for gas tests this type of arrangement is also seen in liquid test of some specific types of valves like flapper type Check Valves & Globe Valves.

This arrangement covers all size ranges for seat and / or body test of valves.

This is arrangement is specifically designed to facilitate easier loading / unloading of Large size Valves on the Test Port which also ensures removal of Air Pockets prior to a Hydro Test.

4 Horizontal Tilting Though mostly suitable for gas tests this type of arrangement is also seen in liquid test of some specific types of valves like flapper type Check Valves & Globe Valves. Because of the horizontal orientation, this arrangement has no obstruction above it & hence gives ease of access to load any type or size of valve easily with a hoist. This arrangement covers all size ranges for seat and / or body test of valves. However, due to limitations on access below the assembly, this type of an arrangement comes only with a compression type clamping with both manual & hydraulic options. This is arrangement is specifically designed to facilitate easier loading / unloading of Large size Valves on the Test Port which also ensures removal of Air Pockets prior to a Hydro Test. When Vertical Valve Test Port comprises of a Body Test clamping assembly loading / unloading large valves that require a hoist for mounting, becomes difficult because of the obstruction due to the clamping plate atop the test port. And if the Test Port is constructed Horizontally so as to enable loading & testing of the valve in Horizontal position, it becomes impossible to remove Air pockets from the valve thoroughly. To eliminate this problem, K.Mass designs and manufactures Test Ports with an ability to rotate in orientation by 90. Using this feature the user can Tilt / Recline the Test Port to horizontal position, load the valve to be tested & Tilt / Incline the Test Port back to Vertical Position for Testing & removal of Air Pockets. In such an arrangement, the valves can be tested at any angle within the rotation range from 0 to 90º. Operator & System Safety with Ease of ) Operation - At K.Mass Safety of the operator as well as the equipment is primary. To ensure adequate safety the following features are incorporated in all Test systems:- STANDARD Electronic Over-Pressure Protection System The Electronic Over Pressure Protection System (EOPPS) enables the user to preset / define the maximum pressure limit for system & avoids accidents due to over-pressure The Peak Pressure Rating of the Test Bench on each test media is preset in the system program & cannot be increased. However this system enables the user to lower this limit to any desired value & ensure that the system is safe against over-pressure. Along with a Digital Pressure Read Out it also gives the user the option & flexibility to select the Units of measure, Least Count & Test Media The EOPPS comes with a built-in calibration feature that enables the user to calibrate the system using a Master gauge as per their periodic calibration schedule Page 4 of 7

Safety Valves on Accumulators The high as well as low Pressure accumulators installed in our Test Benches are equipped with Safety valves carefully selected to ensure adequate

These Safety Valves are Designed & Manufactured In-house by K.Mass Stainless Steel Accumulators All K.

These Accumulators are manufactured using the most modern Designs, Machining & fabrication techniques.

These Safety Screens protect the operator from direct exposure to the line of Valve Under Pressure.

Mass Test Equipment are routed neatly in accordance with international standards using conduits & covers with appropriate glands, clamps & gaskets.

5 Safety Valves on Accumulators The high as well as low Pressure accumulators installed in our Test Benches are equipped with Safety valves carefully selected to ensure adequate discharge incase of Over Pressure in the system. This is a secondary Safety measure over, above and besides the Digital Over Pressure Protection System. These Safety Valves are Designed & Manufactured In-house by K.Mass Stainless Steel Accumulators All K.Mass Test Benches are installed with Stainless Steel Liquid and/or Gas Accumulators which provide for Test Media Volumizing, Pulsation dampening & Pressure Accumulation. These Accumulators are manufactured using the most modern Designs, Machining & fabrication techniques. Safety Screens To ensure Safety of the Operator during testing, our Test Benches come with Safety Screens installed in all relevant critical locations. These Safety Screens protect the operator from direct exposure to the line of Valve Under Pressure. IP 65 compliant Electricals (IP 67 Available on Request) All electrical mountings & cables in K.Mass Test Equipment are routed neatly in accordance with international standards using conduits & covers with appropriate glands, clamps & gaskets. Well labeled tags & circuit diagrams are provided for correlation & maintenance. OPTIONAL Safety Interlock System Taking Safety to the next level, this feature is suavely programmed to ensure utmost safety of the operator & the object under test. As the name suggest, this system interlinks the Test System to the Clamping System. To summarize, the Test System does not pressurize the objects unless all active ports are securely clamped & once the pressure builds in the test System & the Object, the Clamping system does not release the objects unless all active ports are completely depressurized, thus making it fail safe. Page 5 of 7

Interactive Touch Screen Controls with Guide Mode To assist beginner level users conducting High pressure or large size testing, K.

Based on the pre programmed safety parameters, the Test as well as the clamping system automatically regulates the pressure set points & other variables within safe limits for that

Durability & Finish - All Structures, sheet metal & trim / wetted components manufactured by K.

Mass Test Equipment are fabricated from Carbon Steel as per IS 226 with continuous weld construction to form a rigid structure.

Multi-Layer Industrial Grade Painting All carbon steel structures & sheet metal undergo a 5 layer Industrial grade Air spray painting process.

6 Interactive Touch Screen Controls with Guide Mode To assist beginner level users conducting High pressure or large size testing, K.Mass has developed an Interactive touch Screen User Interface with a pre programmed Guide Mode. This feature enables the user to feed in valve & test data in to the system. Based on the pre programmed safety parameters, the Test as well as the clamping system automatically regulates the pressure set points & other variables within safe limits for that particular testing. Such a feature prevents accidents due to human errors & ensures safe & accurate testing. Durability & Finish - All Structures, sheet metal & trim / wetted components manufactured by K.Mass undergo finishing & Coating Pre & Post manufacturing processes to ensure integrity & durability. Skid Frames as per IS 226 Aluminum Checkered Flooring The Skid Frames of all K.Mass Test Equipment are fabricated from Carbon Steel as per IS 226 with continuous weld construction to form a rigid structure. Eyebolts are provided for lifting & easy movement of the units. All skid floors are laid out with Industrial Grade Checkered Plate flooring for easy workflow & adequate workspace. Multi-Layer Industrial Grade Painting All carbon steel structures & sheet metal undergo a 5 layer Industrial grade Air spray painting process. Structures are phosphate coated post sanding & Clear coated post painting. Such a process ensures a minimal of 125 to 150 micron durable coat thickness. Electro-Polished Stainless Steel Trim All Stainless Steel trim & wetted parts installed in K.Mass Test Equipment undergo an electro-polish process post manufacturing. This not only adds to the aesthetic value of the trim but also facilitates for easy observation of deformities / abnormalities, if any over lengthy cyclic usage. Page 6 of 7

Mass Test Equipment undergo a Phosphate Coating process, while

7 Phosphate & Powder Coated Carbon Steel Trim All carbon steel trim components & accessories in K.Mass Test Equipment undergo a Phosphate Coating process, while all Carbon steel vessels undergo a Powder coating process to prevent corrosion. Page 7 of 7

OPERATING AND MAINTENANCE MANUAL BATCH PRESSURE FILTER 3 GALLON CAPACITY

OPERATING AND MAINTENANCE MANUAL BATCH PRESSURE FILTER 3 GALLON CAPACITY SEPOR, INC 718 N FRIES AVE. WILMINGTON, CA 90744 310 830 6601 Fax: 310 830 9336 info@sepor.com Installation The 3 gallon batch pressure